Z-45/22 Service Manual

1 TechnicalPublicationsSecond Edition, First PrintingPart No. 32960 ServiceManualZ-4522 Genie Z-45/22 Part No. 32960 Service Manual - Second EditioniiImportantRead, understand and obey the safety rules andoperating instructions in the Genie Z-45/22 Operator's Manual before attempting anymaintenance or repair Service Manual covers the Genie Z-45/222WD and 4WD models introduced in Manual provides detailed scheduledmaintenance information for the machine ownerand user. It also provides troubleshooting andrepair procedures for qualified mechanical, hydraulic and electrical skillsare required to perform most , several procedures require specializedskills, tools, lifting equipment and a suitableworkshop.

2 In these instances, we stronglyrecommend that maintenance and repair beperformed at a Genie dealer Service Industries has endeavored to deliver thehighest degree of accuracy possible. However,continuous improvement of our products is aGenie policy. Therefore product specifications aresubject to change without are encouraged to notify Genie of errorsand send in suggestions for improvement. Allcommunications will be carefully considered forfuture printings of this and other manuals. Pleasewrite to the technical publications team in care ofGenie Industries, PO Box 69, Redmond WA98073-0069 you have any questions, call Genie Industries. Genie North AmericaTelephone (206) 881-1800 Toll Free in 800 536-1800 Toll Free in Canada 800 426-8089 Fax (206) 883-3475 Genie EuropeTelephone (44) 0636-813943 Fax (44) 0636-815270 IntroductionCopyright 1994 by Genie IndustriesSecond Edition:First Printing, August 1994 Genie is a registered trademarkof Genie Industries Registered 2009987 These machines comply withANSI/SIA Printed on recycled paperPatents PendingPrinted in No.

3 32960 Genie Z-45/22 Service Manual - Second EditionImportantVerify Correct ManualDo not read any further until youhave verified that this is thecorrect Manual for this Genie Industries if youhave any Manual covers the GenieZ-45/22 2WD and 4WD models produced fromMay 1994, starting with serial serial number plate islocated under the engineside turntable cover. It issecured to the bulkheadnear the hydraulic the Genie Z-45/22 Service Manual , FirstEdition, part number 29487, to Service machinesnot covered in this second not use thismanual with theGenie Z-45/22 DC,Bi-fuel, Tri-fuel, Dieseland Gas/LPG turntablecover size and Z-45/22 Part No. 32960 Service Manual - Second EditionThis page intentionally left No.

4 32960 Genie Z-45/22 Service Manual - Second EditionvSafety RulesSection 1 - Safety RulesDangerFailure to obey the instructions and safety rules inthis Manual , and the Genie Z-45/22 OperatingInstruction Manual will result in death or of the hazards identified in the operatinginstruction Manual are also safety hazards whenmaintenance and repair procedures Not Perform MaintenanceUnless:You are trained and qualified to performmaintenance on this read, understand and obey:- manufacturer s instructions and safety rules- employer s safety rules and worksiteregulations- applicable governmental regulationsYou have the appropriate tools, liftingequipment and a suitable Z-45/22 Part No.

5 32960 Service Manual - Second EditionSAFETY RULESviSection 1 - Safety RulesWorkplace SafetyBe sure to keep sparks, flames andlighted tobacco away from flammable andcombustible materials like battery gasesand engine fuels. Always have an approved fireextinguisher within easy sure that all tools and working areasare properly maintained and ready foruse. Keep work surfaces clean and freeof debris that could get into machine componentsand cause sure that your workshop or work areais properly ventilated and well sure any forklift, overhead crane orother lifting or supporting device is fullycapable of supporting and stabilizing theweight to be lifted. Use only chains or straps thatare in good condition and of ample sure that fasteners intended for onetime use ( , cotter pins and self-lockingnuts) are not reused.

6 These componentsmay fail if they are used a second sure to properly dispose of old oil orother fluids. Use an approved be environmentally SafetyAny person working on or around a machine mustbe aware of all known safety hazards. Personalsafety and the continued safe operation of themachine should be your number one each procedure thoroughly. Thismanual and the decals, on the machine,use signal words to identify the following:Indicates the presence ofa hazard that will causedeath or serious the presence ofa hazard that may causedeath or serious the presence ofa hazard that will or maycause serious injury ordamage to the specialoperation or sure to wear protective eye wear andother protective clothing if the situationwarrants aware of potential crushing hazardssuch as moving parts, free swinging orunsecured components, and lifting orplacing loads.

7 Always wear approved No. 32960 Genie Z-45/22 Service Manual - Second EditionTable of ContentsviiIntroductionImportant OneSafety RulesGeneral Safety Rules ..iiiSection TwoSpecificationsMachine 2 - 1 Performance 2 - 2 Hydraulic 2 - 2 Ford LSG 423 Engine 2 - 5 Deutz F3L Engine 2 - 7 Section ThreeScheduled Maintenance 3 - 1 Table A .. 3 - 2 Table B .. 3 - 3 Table 3 - 5 Table 3 - 6 Maintenance Inspection 3 - 7 Section FourScheduled Maintenance 4 - 1A-1 Inspect the 4 - 2A-2 Inspect the Decals and Placards ..4 - 2A-3 Inspect for Damage, Loose or Missing Parts .. 4 - 2A-4 Check the Engine Oil Level .. 4 - 3A-5 Check the Engine Coolant Level - Gasoline/LPG 4 - 3A-6 Check for Fuel 4 - 3A-7 Check the Hydraulic Oil Level.

8 4 - 4A-8 Check for Hydraulic 4 - 4A-9 Check Tire 4 - 5 Genie Z-45/22 Part No. 32960 Service Manual - Second EditionSection FourScheduled Maintenance Procedures, continuedA-10 Test the Platform and Ground Controls .. 4 - 5A-11 Test Auxiliary Power 4 - 5A-12 Test the Tilt Level Sensor .. 4 - 6A-13 Test the Limit 4 - 6A-14 Replace the Engine Oil and Filter - Gasoline/LPG 4 - 8A-15 Change the Engine Air Filter .. 4 - 10B-1 Check the Engine Belt(s) ..4 - 11B-2 Check the Radiator - Gasoline/LPG Models .. 4 - 11B-3 Check the Oil Cooler and Cooling Fins - Deutz Diesel 4 - 11B-4 Check the Exhaust 4 - 12B-5 Check the Battery .. 4 - 12B-6 Check the Hydraulic Tank Filter Condition 4 - 13B-7 Inspect the Electrical 4 - 13B-8 Inspect the Tires and Wheels (including lug nut torque).

9 4 - 14B-9 Confirm Proper Brake 4 - 14B-10 Check the Oil Level in the Torque 4 - 15B-11 Check and Adjust the Engine Idle Mixture - Gasoline/LPG 4 - 15B-12 Check and Adjust the Engine RPM .. 4 - 15B-13 Test the Key 4 - 17B-14 Test the Emergency Stop Buttons .. 4 - 18B-15 Test the Ground Control Override .. 4 - 18B-16 Test the Oscillate 4 - 18B-17 Test Platform 4 - 19B-18 Test the Service 4 - 19B-19 Test the Foot 4 - 20B-20 Test the Engine Idle Select .. 4 - 20B-21 Test Fuel Select Operation - Gasoline/LPG 4 - 21B-22 Test the Turntable Rotation Stop .. 4 - 21 TABLE OF CONTENTSiixPart No. 32960 Genie Z-45/22 Service Manual - Second EditionSection FourScheduled Maintenance Procedures, continuedB-23 Test the Drive Enable System.

10 4 - 21B-24 Test the Drive 4 - 22B-25 Test Drive Speed - Stowed Position .. 4 - 23B-26 Test the Alarm Package (optional equipment) .. 4 - 23B-27 Perform Hydraulic Oil 4 - 24B-28 Replace the Engine Oil and Filter - Deutz Diesel 4 - 24C-1 Check the Primary Boom Wear Pads .. 4 - 26C-2 Check the Turntable Rotation Bearing Bolts .. 4 - 26C-3 Check the Free-wheel 4 - 27C-4 Grease the Worm Drive Gear .. 4 - 28C-5 Replace the Torque Hub Oil .. 4 - 29C-6 Replace the Hydraulic Tank Filter .. 4 - 29C-7 Replace the Drive Loop Hydraulic Filter .. 4 - 30C-8 Replace the Diesel Fuel Filter .. 4 - 30C-9 Replace the Gasoline Fuel Filter .. 4 - 31C-10 Replace the PCV Valve - Gasoline/LPG Models.