Genie Z-45/22 User manual

Technical
Publications
First Edition
Part No. 29487
®
Service
Manual
Z-45 22

Genie Z-45/22 Part No. 29487
Service Manual - First Edition
ii
Important
Read, understand and obey the safety rules and
operating instructions in the Genie Z-45/22
Operating Instruction Manual before attempting
any maintenance or repair procedure.
This service manual covers the Genie Z-45/22
2WD and 4WD models introduced in 1991.
This manual provides detailed scheduled
maintenance information for the machine owner
and user. It also provides troubleshooting and
repair procedures for qualified service
professionals.
Basic mechanical, hydraulic and electrical skills
are required to perform most procedures.
However, several procedures require specialized
skills, tools, lifting equipment and a suitable
workshop. In these instances, we strongly
recommend that maintenance and repair be
performed at a Genie dealer service center.
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 other manuals. Please
write to the technical publications team in care of
Genie Industries, PO Box 69, Redmond WA
98073-0069 USA.
If you have any questions, call Genie Industries.
®
®
Genie U.S.A. and Canada
Telephone [phone]
Toll Free 800 536-1800
Fax [phone]
Telex 152351
Genie Europe
Telephone [phone]
Fax [phone]
Introduction
Copyright©1992byGenieIndustries
FirstEdition,October1992
Genie®isaregisteredtrademark
ofGenieIndustries
Registered2009987
Printed on recycled paper
PrintedinU.S.A.

Part No. 29487 Genie Z-45/22
Service Manual - First Edition
iii
Safety Rules
Section 1 - Safety Rules
Danger
Failure to obey the instructions and safety rules in
this manual, and the Genie Z-45/22 Operating
Instruction Manual will result in death or serious
injury.
Many of the hazards identified in the operating
instruction manual are also safety hazards when
maintenance and repair procedures are
performed.
Do Not Perform Maintenance
Unless:
You are trained and qualified to perform
maintenance on this machine.
You read, understand and obey:
- manufacturer’s instructions and safety rules
- employer’s safety rules
- applicable governmental regulations
You have the appropriate tools, lifting
equipment and a suitable workshop.

Genie Z-45/22 Part No. 29487
Service Manual - First Edition
SAFETY RULES
iv
Section 1 - Safety Rules
WorkplaceSafety
Be sure to keep sparks, flames and
lighted tobacco away from flammable and
combustible materials like battery gases
and engine fuels. Always have an approved fire
extinguisher within easy reach.
Be sure that all tools and working areas
are properly maintained and ready for
use. Keep work surfaces clean and free
of debris that could get into machine components
and cause damage.
Be sure that your workshop or work area
is well ventilated and safely and
adequately illuminated.
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 mindful of the environment.
PersonalSafety
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 number one priority.
Read each procedure thoroughly. This
manual and the decals, on the machine,
use signal words to identify the following:
Indicates the presence of
a hazard that will cause
death or serious injury.
Indicates the presence of
a hazard that may cause
death or serious injury.
Indicates the presence of
a hazard that will or may
cause serious injury or
damage to the machine.
Indicates special
operation or maintenance
information.
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, and lifting or
placing loads. Always wear approved steel-toed
shoes.

Part No. 29487 Genie Z-45/22
Service Manual - First Edition
Table of Contents
v
Introduction
Important Information ..................................................................................................... ii
Section One Safety Rules
General Safety Rules .................................................................................................... iii
Section Two Specifications
Machine Specifications............................................................................................. 2 - 1
Performance Specifications...................................................................................... 2 - 2
Hydraulic Specifications ........................................................................................... 2 - 2
Ford LSG 423 Engine Specifications........................................................................ 2 - 5
Kubota V1702-B Engine Specifications .................................................................... 2 - 7
Section Three Scheduled Maintenance Inspections
Introduction............................................................................................................... 3 - 1
Table A ..................................................................................................................... 3 - 2
Table B ..................................................................................................................... 3 - 3
Table C..................................................................................................................... 3 - 4
Table D..................................................................................................................... 3 - 5
Maintenance Inspection Report................................................................................ 3 - 6
Section Four Scheduled Maintenance Procedures
Introduction............................................................................................................... 4 - 1
A-1 Inspect the Operating Instruction and Safety Manuals ................................... 4 - 2
A-2 Inspect the Decals and Placards .................................................................... 4 - 2
A-3 Inspect for Damage, Loose or Missing Parts.................................................. 4 - 2
A-4 Check the Engine Oil Level............................................................................. 4 - 3
A-5 Check the Engine Coolant Level..................................................................... 4 - 3
A-6 Check for Fuel Leaks...................................................................................... 4 - 3
A-7 Check the Hydraulic Oil Level......................................................................... 4 - 4
A-8 Check for Hydraulic Leaks.............................................................................. 4 - 4
A-9 Check Tire Pressure ....................................................................................... 4 - 4

Genie Z-45/22 Part No. 29487
Service Manual - First Edition
Section Four Scheduled Maintenance Procedures, continued
A-10 Test the Platform and Ground Controls .......................................................... 4 - 5
A-11 Test Auxiliary Power Operation ...................................................................... 4 - 5
A-12 Test the Tilt Level Sensor............................................................................... 4 - 6
A-13 Test the Limit Switches................................................................................... 4 - 6
A-14 Replace the Engine Oil and Filter ................................................................... 4 - 8
A-15 Change the Engine Air Filter........................................................................... 4 - 9
A-16 Drain the Fuel Filter/Water Separator - Diesel Models ................................. 4 - 10
B-1 Check the Engine Fan Belts ......................................................................... 4 - 11
B-2 Check the Radiator ....................................................................................... 4 - 11
B-3 Check the Exhaust System .......................................................................... 4 - 11
B-4 Check the Battery ......................................................................................... 4 - 12
B-5 Check the Hydraulic Reservoir Filter Condition Indicator.............................. 4 - 12
B-6 Inspect Electrical Wiring ............................................................................... 4 - 13
B-7 Inspect the Tires and Wheels ....................................................................... 4 - 13
B-8 Confirm Proper Brake Configuration............................................................. 4 - 14
B-9 Check the Oil Level in the Torque Hubs ....................................................... 4 - 14
B-10 Check the Engine Choke - Gasoline/LPG Models ........................................ 4 - 15
B-11 Check the Glow Plugs - Diesel Models......................................................... 4 - 15
B-12 Check and Adjust the Engine Idle Mixture - Gasoline/LPG Models .............. 4 - 16
B-13 Check and Adjust the Engine RPM............................................................... 4 - 16
B-14 Test the Key Switch...................................................................................... 4 - 17
B-15 Test the Emergency Stop Buttons................................................................ 4 - 18
B-16 Test the Ground Control Override ................................................................ 4 - 18
B-17 Test the Oscillate Lock-out ........................................................................... 4 - 18
B-18 Test Platform Self-leveling............................................................................ 4 - 19
B-19 Test the Service Horn ................................................................................... 4 - 19
B-20 Test the Foot Switch..................................................................................... 4 - 19
B-21 Test the Engine Speed Select ...................................................................... 4 - 20
B-22 Test Fuel Select Operation - Gasoline/LPG Models ..................................... 4 - 20
B-23 Test the Turntable Rotation Stop.................................................................. 4 - 21
TABLE OF CONTENTS
vi

Part No. 29487 Genie Z-45/22
Service Manual - First Edition
Section Four Scheduled Maintenance Procedures, continued
B-24 Test the Drive Enable System ...................................................................... 4 - 21
B-25 Test the Drive Brakes ................................................................................... 4 - 22
B-26 Test Drive Speed - Stowed Position ............................................................. 4 - 22
B-27 Test the Alarm Package (optional equipment).............................................. 4 - 23
C-1 Check the Primary Boom Wear Pads ........................................................... 4 - 24
C-2 Check the Turntable Rotation Bearing Bolts................................................. 4 - 24
C-3 Check the Free-wheel Feature ..................................................................... 4 - 25
C-4 Grease the Worm Drive Gear ....................................................................... 4 - 26
C-5 Replace the Torque Hub Oil ......................................................................... 4 - 27
C-6 Replace the Hydraulic Reservoir Filter ......................................................... 4 - 27
C-7 Replace the Drive Loop Hydraulic Filter ....................................................... 4 - 28
C-8 Replace the Diesel Fuel Filter....................................................................... 4 - 28
C-9 Replace the Gasoline Fuel Filter................................................................... 4 - 29
C-10 Replace the PCV Valve - Gasoline/LPG Models .......................................... 4 - 30
C-11 Clean or Replace the Distributor Cap and Rotor - Gasoline/LPG Models..... 4 - 30
C-12 Replace the Spark Plugs - Gasoline/LPG Models ........................................ 4 - 31
C-13 Check and Adjust the Air/Propane Mixture - Gasoline/LPG Models ............. 4 - 31
C-14 Check and Adjust the Ignition Timing - Gasoline/LPG Models ..................... 4 - 32
D-1 Change The Hydraulic Oil............................................................................. 4 - 33
D-2 Change or Recondition the Engine Coolant .................................................. 4 - 34
D-3 Change the Fuel Lines.................................................................................. 4 - 35
D-4 Check Engine Valve Clearance - Gasoline/LPG Models .............................. 4 - 36
D-5 Check Engine Cylinder Compression - Gasoline/LPG Models ..................... 4 - 36
D-6 Clean PCV Hoses, Tubes, and Fittings - Gasoline/LPG Models .................. 4 - 37
D-7 Check the Engine Nozzle Injection Pressure - Diesel Models ...................... 4 - 38
D-8 Check Injection Timing - Diesel Models........................................................ 4 - 38
D-9 Replace The Timing Belt - Ford.................................................................... 4 - 38
TABLE OF CONTENTS
vii

Genie Z-45/22 Part No. 29487
Service Manual - First Edition
Section Five Troubleshooting Flow Charts
Introduction............................................................................................................... 5 - 1
1 Engine Will Not Crank Over............................................................................ 5 - 3
2 Engine Cranks But Will Not Start - Gasoline/LPG Models.............................. 5 - 4
3 Engine Cranks But Will Not Start - Diesel Models .......................................... 5 - 9
4 Engine Choke Inoperative - Gasoline/LPG Models....................................... 5 - 11
5 Engine Glow Plugs Inoperative - Diesel Models
See B-11, Check The Glow Plugs ................................................................ 4 - 15
6 Engine Will Not Start On LPG, But Will Start On Gasoline
- Gasoline/LPG Models................................................................................. 5 - 13
7 Engine Will Not Start On Gasoline, But Will Start On LPG
- Gasoline/LPG Models................................................................................. 5 - 14
8 Engine High Idle Inoperative - Gasoline/LPG Models ................................... 5 - 15
9 Engine Low Idle Inoperative - Gasoline/LPG Models.................................... 5 - 17
10 Engine High Idle Inoperative - Diesel Models ............................................... 5 - 18
11 Engine Low Idle Inoperative - Diesel Models ................................................ 5 - 19
12 All Functions Inoperative, Engine Starts and Runs....................................... 5 - 20
13 All Lift and Steer Functions Inoperative, Drive Functions Operational.......... 5 - 21
14 Ground Controls Inoperative, Platform Controls Operate Normally .............. 5 - 22
15 Platform Controls Inoperative, Ground Controls Operate Normally .............. 5 - 23
16 Secondary Boom Up Function Inoperative ................................................... 5 - 24
17 Secondary Boom Down Function Inoperative............................................... 5 - 27
18 Primary Boom Up Function Inoperative ........................................................ 5 - 29
19 Primary Boom Down Function Inoperative ................................................... 5 - 31
20 Primary Boom Extend Function Inoperative ................................................. 5 - 33
21 Primary Boom Retract Function Inoperative ................................................. 5 - 35
22 Turntable Rotate Function Inoperative.......................................................... 5 - 36
23 Turntable Rotate Left Function Inoperative................................................... 5 - 38
24 Turntable Rotate Right Function Inoperative ................................................ 5 - 39
25 All Platform Leveling Functions Inoperative.................................................. 5 - 40
26 Platform Level Up Function Inoperative........................................................ 5 - 41
27 Platform Level Down Function Inoperative ................................................... 5 - 42
TABLE OF CONTENTS
viii

Part No. 29487 Genie Z-45/22
Service Manual - First Edition
Section Five Troubleshooting Flow Charts, continued
28 Platform Rotate Left Function Inoperative .................................................... 5 - 43
29 Platform Rotate Right Function Inoperative .................................................. 5 - 44
30 Oscillate Lock-out Function Inoperative........................................................ 5 - 45
31 Steer Left Function Inoperative..................................................................... 5 - 46
32 Steer Right Function Inoperative .................................................................. 5 - 47
33 All Drive Functions Inoperative, All Other Functions Operate Normally........ 5 - 48
34 Drive Forward Or Reverse Function Inoperative .......................................... 5 - 50
35 High Range Drive Function Inoperative ........................................................ 5 - 51
36 Low Range Drive Function Inoperative......................................................... 5 - 53
37 Machine Will Not Drive At Full Speed ........................................................... 5 - 54
38 Machine Drives At Full Speed With Platform Elevated ................................. 5 - 55
39 Drive Enable System Is Malfunctioning ........................................................ 5 - 56
40 Auxiliary Functions Inoperative ..................................................................... 5 - 57
Section Six Schematics
Introduction................................................................................................................. 6-1
Electrical Symbol Legend ........................................................................................... 6-2
Electrical Schematic - Gasoline/LPG Models ............................................................. 6-3
Ground Control Box Legend - Gasoline/LPG Models................................................. 6-5
Relay Panel Legend - Gasoline/LPG Models ............................................................. 6-6
Platform Control Box Legend - Gasoline/LPG Models ............................................... 6-7
Electrical Schematic - Diesel Models ......................................................................... 6-8
Ground Control Box Legend - Diesel Models ........................................................... 6-10
Relay Panel Legend - Diesel Models........................................................................ 6-11
Platform Control Box Legend - Diesel Models.......................................................... 6-12
Hydraulic Symbols Legend....................................................................................... 6-13
2WD Hydraulic Schematic........................................................................................ 6-14
4WD Hydraulic Schematic........................................................................................ 6-15
TABLE OF CONTENTS
ix

Genie Z-45/22 Part No. 29487
Service Manual - First Edition
Section Seven Repair Procedures
Introduction............................................................................................................... 7 - 1
Platform Controls
1-1 Joystick Controllers......................................................................................... 7 - 2
1-2 Horsepower Limiter Board .............................................................................. 7 - 6
1-3 Foot Switch..................................................................................................... 7 - 8
1-4 Resistors......................................................................................................... 7 - 8
1-5 Toggle Switches ............................................................................................. 7 - 9
Platform Components
2-1 Platform ........................................................................................................ 7 - 10
2-2 Platform Leveling Slave Cylinder .................................................................. 7 - 10
2-3 Platform Rotator ........................................................................................... 7 - 11
Primary Boom Components
3-1 Plastic Cable Track....................................................................................... 7 - 13
3-2 Primary Boom ............................................................................................... 7 - 13
3-3 Primary Boom Lift Cylinder ........................................................................... 7 - 16
3-4 Extension Cylinder........................................................................................ 7 - 18
3-5 Platform Leveling Master Cylinder ................................................................ 7 - 19
Secondary Boom Components
4-1 Secondary Boom .......................................................................................... 7 - 21
4-2 Secondary Boom Lift Cylinders..................................................................... 7 - 26
Turntable Covers
5-1 Turntable Covers .......................................................................................... 7 - 27
Kubota V1702-B Engine
6-1 Timing Adjustment ........................................................................................ 7 - 28
6-2 Glow Plugs.................................................................................................... 7 - 28
6-3 RPM Adjustment........................................................................................... 7 - 28
6-4 Flex Plate...................................................................................................... 7 - 28
6-5 Water Temperature and Oil Pressure Switches............................................ 7 - 28
Ford LSG 423 Engine
7-1 Governor Actuator ........................................................................................ 7 - 30
TABLE OF CONTENTS
x

Part No. 29487 Genie Z-45/22
Service Manual - First Edition
TABLE OF CONTENTS
xi
Section Seven Repair Procedures, continued
7-2 Choke Adjustments....................................................................................... 7 - 31
7-3 Timing Adjustment ........................................................................................ 7 - 32
7-4 Carburetor Adjustment.................................................................................. 7 - 32
7-5 RPM Adjustment........................................................................................... 7 - 32
7-6 Flex Plate...................................................................................................... 7 - 32
7-7 Water Temperature and Oil Pressure Switches............................................ 7 - 33
7-8 Vacuum Switch ............................................................................................. 7 - 34
Ground Controls
8-1 Control Relays .............................................................................................. 7 - 35
8-2 Toggle Switches, See 1-5, Toggle Switches................................................... 7 - 9
8-3 Wago®Components ..................................................................................... 7 - 36
8-4 Resistors....................................................................................................... 7 - 37
Relay Panel
9-1 Control Relays .............................................................................................. 7 - 38
9-2 Power Relay ................................................................................................. 7 - 39
Hydraulic Pumps
10-1 Lift/Steer Pump............................................................................................. 7 - 40
10-2 Drive Hydraulic Pump ................................................................................... 7 - 41
Function Manifold
11-1 Function Manifold Components .................................................................... 7 - 42
11-2 Valve Adjustments ........................................................................................ 7 - 44
Fuel and Hydraulic Tanks
12-1 Hydraulic Reservoir ...................................................................................... 7 - 46
12-2 Fuel Tank...................................................................................................... 7 - 47
Turntable Rotation Components
13-1 Rotation Hydraulic Motor .............................................................................. 7 - 48
13-2 Rotation Bearing and Worm Drive ................................................................ 7 - 48
2WD Steering Axle Components
14-1 Yoke and Hub ............................................................................................... 7 - 53
14-2 Steering Cylinders ........................................................................................ 7 - 54

Genie Z-45/22 Part No. 29487
Service Manual - First Edition
Section Seven Repair Procedures, continued
14-3 Tie Rod ......................................................................................................... 7 - 55
4WD Steering Axle Components
15-1 Yoke and Hub ............................................................................................... 7 - 56
15-2 Steering Cylinders, See 14-2, Steering Cylinders......................................... 7 - 57
15-3 Tie Rod, See 14-3, Tie Rod .......................................................................... 7 - 55
Oscillating Axle Components
16-1 Oscillating Axle Lock-out Cylinder ................................................................ 7 - 58
Steer and Oscillate Manifold
17-1 Steer and Oscillate Manifold Components.................................................... 7 - 59
17-2 Valve Adjustments ........................................................................................ 7 - 60
Non-steering Axle Components
18-1 Drive Motor ................................................................................................... 7 - 61
18-2 Torque Hub................................................................................................... 7 - 61
2WD Drive Manifold
19-1 2WD Drive Manifold Components................................................................. 7 - 62
19-2 Valve Adjustments ........................................................................................ 7 - 64
4WD Drive Manifold
20-1 4WD Drive Manifold Components................................................................. 7 - 66
20-2 Valve Adjustments ........................................................................................ 7 - 68
TABLE OF CONTENTS
xii

Part No. 29487 Genie Z-45/22 2 - 1
Section 2 - SpecificationsService Manual - First Edition
59 sq in 43.5 sq in
380sq cm 280sq cm
35.8 inches 28 inches
91cm 71cm
17.5 inches 14.5 inches
10.5 inches 7 inches
9 @ 5/8-18
8 @ 5/8-18 8 @ 5/8-18
9 @ 5/8-18 9 @ 5/8-18
125 ft-lbs 125 ft-lbs
169.5 Nm 169.5 Nm
Specifications
MachineSpecifications
14-17.5NHS 9-14.5 LT
8 Tread 8
Sidewall 6
15 gallons
56.8 liters
33.5 pounds
15.2kg
25 gallons
95 liters
30 gallons
114 liters
17 ounces
0.5 liters
Fluid capacities
Fuel tank
Propane tank
Hydraulic tank
Hydraulic system
(including tank)
Torque hubs
Continuous improvement of our products is a
Genie policy. Product specifications are subject to
change without notice.
40 psi 100 psi
2.76 bar 6.89 bar
28 psi
1.93 bar
Tires and wheels Rough terrain Industrial
Wheel diameter
Wheel width
Wheel lugs - 4WD
Wheel lugs - 2WD
Front
Rear
Lug nut torque
Tire size
Tire ply rating
Tire contact area
Overall tire diameter
Tire pressure - 2WD
4WD
17 ft 81/2in 17 ft 10 3/4in
5.4m 5.45m
6 ft 8 1/4in 6 ft 4 5/8in
203.8cm 194.6cm
5 ft 9 5/8in
176.8cm
6 ft 6 in 7 ft 4 in
1.98m 2.23m
13860 lbs 14410 lbs
6287kg 6536kg
8 in 11 in
20.3cm 27.9cm
6 ft 6 ft
182.8cm 182.8cm
30 in 30 in
76.2cm 76.2cm
45 ft 45 ft
13.72m 13.72m
23 ft 23 ft
7m 7m
21 ft 7 in 21 ft 7 in
6.58m 6.58m
1 inch none
2.54cm
6 ft 3 in 6 ft 3 in
190.5cm 190.5cm
14 ft 4 in 14 ft 9 in
4.37m 4.49m
7 ft 6 ft 8 in
2.13m 2.03m
359° 359°
180° 180°
Stowed dimension 2WD 4WD
Length
Width
Rough terrain
Industrial
Height
Weight
Ground clearance
Platform dimensions
Length
Width
Operational dimensions
Maximum plaform height
Maximum platform reach
Maximum up-and-over
clearance
Maximum turret tailswing
Wheelbase
Minimum turning radius,
outside
Minimum turning radiius,
inside
Turret rotation
Platform rotation

2 - 2 Genie Z-45/22 Part No. 29487
Section 2 - Specifications Service Manual - First Edition
5.0 mph 4.8 mph
8.0km/h 7.7km/h
1.1 mph 0.9 mph
1.8km/h 1.4km/h
or 5 feet or 4 feet
in 3 sec. in 3 sec.
0.68 mph / 1km/h
or 1 foot per second
0.4 mph / 0.65km/h
or 0.59 feet per second
30% 40%
29 seconds
25 seconds
27 seconds
35 seconds
25 seconds
25 seconds
73 seconds
15 seconds
25 seconds
15 seconds
60 seconds
60 seconds
Dexron II equivalent
bi-directional variable
displacement piston
pump
0 - 25 gpm
0 - 1.6 liters/second
3500 psi
241.3 bar
360 psi / 24.8 bar
3 micron
50 psi / 345kPa
350 psi
24.1 bar
3.0 gpm
11.4 liters/minute
4.5 gpm
17.0 liters/minute
SPECIFICATIONS
PerformanceSpecifications
Drive speeds, maximum 2WD 4WD
Boom lowered, high range
Boom lowered, low range
Boom raised, high range
Boom raised, low range
Gradeability (stowed)
Boom function speeds maximum
from platform controls
Boom extend
Boom retract
Primary boom lift
Primary boom lower
Secondary boom lift
Secondary boom lower
Turntable rotate (359°)
Platform rotate (180°)
Platform level up
Platform level down
Multiple function
stowed to full raised
Multiple function
full lowered to stowed
HydraulicSpecifications
Hydraulic fluid
Drive pump
Type
Displacement
Maximum drive
pressure
Charge pressure
Medium pressure filter
Medium pressure filter
bypass pressure
Drive manifold
Motor shift/brake
relief pressure
4WD front motor
flow regulators
4WD rear motor
flow regulators

Part No. 29487 Genie Z-45/22 2 - 3
Section 2 - SpecificationsService Manual - First Edition
2.1 cu in / 34.4cc
High - 2.8 cu in / 45.9cc
Low - 0.15 cu in / 2.5cc
2200psi
138 bar
1200 psi
83 bar
1200 psi
83 bar
1.5 gpm
5.7 liters/minute
fixed displacement gear
pump
6.4 gpm @ 2150 rpm
0.4 liters/second
10 micron with 25psi /
172kPa bypass
1800 psi
1600 psi
fixed displacement gear
pump
0.85 gpm
3.2 liters/minute
2030 psi
138 bar
SPECIFICATIONS
Front drive motors - 4WD models
Displacement per revolution
Rear drive motor
Displacement per revolution
Function pump
Type
Displacement
Function circuit return
line filter
Function manifold
Function relief
valve pressure
Secondary down relief
valve pressure
Primary down relief
valve pressure
Steer/oscillate
flow regulator
Steer/oscillate manifold
Sequencing valve
pressure
Accumulator
pre-charge pressure
Auxillary pump
Type
Displacement
Auxillary pump
relief pressure

2 - 4 Genie Z-45/22 Part No. 29487
Section 2 - Specifications Service Manual - First Edition
SPECIFICATIONS
13
20
12
18
11
18
10
16
9
14
8
12
24
32
20
28
18
24
16
24
14
20
Torque - Dry
inch-pounds Torque - Dry foot-pounds Torque - Dry Newton meters Torque - Dry inch-pounds Torque - Dry foot-pounds Torque - Dry Newton meters
43
49
96
120
17
19
30
35
50
55
75
90
110
120
150
170
260
300
430
470
640
700
5
6
11
14
23
28
41
48
68
75
102
122
149
163
204
231
353
407
583
637
868
949
60
68
144
168
25
25
45
50
70
80
110
120
150
170
220
240
380
420
600
660
900
1000
7
8
16
19
34
34
61
68
95
109
149
163
204
231
298
326
515
570
814
895
1221
1356
10
1/4
5/16
3/8
7/16
1/2
9/16
5/8
3/4
7/8
1
Torque specification for lubricated bolts is 25% less than dry torque specification for bolt size.
Size Threads SAE Grade 5 Bolts SAE Grade 8 Bolts
BoltTorqueSpecifications

Part No. 29487 Genie Z-45/22 2 - 5
Section 2 - SpecificationsService Manual - First Edition
12V, Group 24
75A
110 rpm
150A
460A
70A
0.5V DC
0.50 inches / 12.7mm
0.25 inches / 6.35mm
40 ounces
55 - 75 inch-pounds
98 - 134gm-cm
15 - 20 foot-pounds
2.1 - 2.7kg-m
0.005 inches / 0.127mm
SPECIFICATIONS
5.0 - 7.0 psi
1 pint / 473cc in 25
seconds
875A
125 minutes
5W - 30
10W - 30
10W - 40 or 10W - 50
20W - 40 or 20W - 50
40 - 60 psi
275.8 - 413.7kPa
5 quarts / 4.71 liters
0.0010 - 0.0027 inches
0.025 - 0.068mm
0.0015 - 0.0032 inches
0.038 - 0.081mm
140 cu in / 2.3 liters
4
3.780 x 3.126 inches
96 x 79.4mm
63 @4000 rpm
1 - 3 - 4 - 2
2150 rpm
1200 rpm
Precision electronic
psi of lowest cylinder
must be at least 75% of
highest cylinder
Ford Engine LSG-423
Displacement
Number of cylinders
Bore and stroke
Horsepower
Firing order
High engine speed
Low engine speed
Governing
Compression pressure
Valve clearances
Intake
Exhaust
Lubrication System
Oil pressure (operating
temp. @ 2150 rpm)
Oil capacity
(including filter)
Oil viscosity requirements
Below 60°F / 15.5°C
-10 to 90°F / -23 to 32°C
above -10°F / -23°C
above 25°F / -4°C
Use oils meeting API classification SF (labeled SF/CC
or SF/CD) as they offer improved wear protection.
Starter motor
Normal engine
cranking speed
Current draw, normal load
Current draw, maximum load
Current draw, no load
Maximum circuit
voltage drop (normal temp)
Brush length, new
Brush length, wear limit
Brush spring tension
Bolt torque through brush
Brush mounting
bolt torque
Maximum commutator
runout
Battery
Type
Ampere hour
Cold Cranking Ampere
Reserve capacity @ 25A rate
Fuel Pump
Static pressure
Minimum volume flow

2 - 6 Genie Z-45/22 Part No. 29487
Section 2 - Specifications Service Manual - First Edition
10° BTDC
1.13 - 1.25Ω(75°F)
7700 - 9300Ω (75°F)
Motorcraft AWSF-52
0.042 - 0.046 inches
1.07 - 1.18mm
120 - 150 foot-pounds
90 - 120 foot-pounds
11.5 quarts/10.9 liters
35A, 14.5V
28 - 40 38 - 54
6 - 9 8 - 12
28 - 40 38 - 54
14 - 21 19 - 28
50 - 71 68 - 96
6 - 9 8 - 12
7.5 - 15 10 - 20
10 - 14 14 - 19
103 - 133 140 - 180
50 - 60 68 - 81
80 - 90 108 - 122
14 - 21 19 - 28
5 - 8 7 - 11
14 - 19 19 - 26
20 - 30 27 - 41
56 - 64 76 - 87
14 - 21 19 - 28
14 - 21 19 - 28
8 - 18 11 - 24
15 - 25 20 - 34
10 - 13.5 14 - 18
20 - 35 27 - 47
5 - 8 7 - 11
5 - 10 7 - 14
8 - 18 11 - 24
23 - 28 31 - 38
14 - 21 19 - 28
6 - 9 8 - 12
14 - 21 19 - 28
6 - 9 8 - 12
14 - 21 19 - 28
6 - 9 8 - 12
Cylinder head bolt / M-12
torque in sequence:
first step
second step
Distributor clamp bolt / M-10
Distributor vacuum tube
to manifold adaptor
Exhaust manifold to cylinder head bolt or nut / M-10
torque in sequence:
first step
second step
Flywheel to crankshaft bolt / M-10
Fuel pump to cylinder block / M-8
Intake manifold to cylinder
head bolt or nut / M-8
Oil pressure sending
unit to block
Oil pan drain plug to pan / M-14
Oil pan to block / M-6
Oil filter insert to block
Rocker arm cover to
cylinder head / M-6
Spark plug to cylinder
head / M-14
Temperature sending
unit to block / M-14
Water jacket drain plug
to block
Water pump to block bolt
Auxiliary shaft cover bolt / M-6
Water outlet connection
bolt / M-8
Cylinder front cover bolt / M-6
Inner timing belt cover stud / M-8
Outer timing belt cover bolt / M-6
SPECIFICATIONS
Ignition System
Ignition spark advance
Ignition coil
primary resistance
Ignition coil
secondary resistance
Type
Gap
Coolant capacity
Alternator output
Fan belt tension
new
used
Bolt torque specifications
Item / Size Torque Torque
(ft-lbs) (Nm)
Auxiliary shaft gear bolt / M-10
Auxiliary shaft thrust
plate bolt / M-6
Belt tensioner (timing)
pivot bolt / M-10
Belt tensioner (timing)
adjusting bolt / M-8
Camshaft gear bolt / M-12
Camshaft thrust plate bolt / M-6
Carburetor to spacer stud / M-8
Carburetor spacer to
manifold bolt / M-8
Crankshaft damper bolt / M-14

Part No. 29487 Genie Z-45/22 2 - 7
Section 2 - SpecificationsService Manual - First Edition
Bosch K Type
1991 psi / 1437 bar
25° BTDC
Diesel number 2-D
7.25 quarts / 6.9 liters
35A, 14V
176.9 - 182.3°F
80.5 - 83.5°C
203°F / 95°C
90A
0.7480 in. / 19mm
0.5 in. / 12.7mm
65 - 68 88 - 93
22 - 36 29 - 49
43 - 58 59 - 78
72 - 79 98 - 108
8 - 18 11 - 24
15 - 25 20 - 34
5 - 7 7 - 9
17 - 24 24 - 27
8 - 18 11 - 24
12V, Group 24
75A
875A
125 minutes
1.5Ω
0.275-0.354 in / 7 - 9mm
105.7 cu in / 1.732 liters
4
3.23 x 3.23 inches
82 x 82mm
36 @2800 rpm
1 - 3 - 4 - 2
22:1
427 - 469 psi
29.4 - 32.3 bar
2150 rpm
1200 rpm
centrifugal ball
mechanical
0.0071 - 0.0087 inches
0.18 - 0.22mm
42.7 - 64 psi
294.2 - 441.3kPa
9.5 quarts / 9 liters
10W - 30
SPECIFICATIONS
KubotaEngineV1702-B
Starter motor
Current draw, no load
Brush length, new
Brush length, minimum
Battery
Type
Ampere hour
Cold cranking ampere
Reserve capacity @ 25A rate
Glow plug resistance
Fan belt tension
Bolt torque specifications
Item Torque Torque
(ft-lbs) (Nm)
Cylinder head bolt
Fuel injector nozzle holder
to cylinder head
Fuel injector retaining nut
to nozzle holder body
Flywheel to crankshaft bolt
Oil pressure sending
unit to block
Oil pan drain plug to pan
Rocker arm cover to
cylinder head
Rocker arm mounting nuts
Temperature sending
unit to block
Thermostat
Beginning opening
Full-open
Displacement
Number of cylinders
Bore and stroke
Horsepower
Firing order
Compression ratio
Compression pressure
High engine speed
Low engine speed
Governing
Valve clearance, cold
Lubrication System
Oil pressure
Oil capacity
including filter
Oil viscocity
requirements
Engine oil should be MIL-L-2104C or have properties of
API classification CC/CD/CE grades.
Injection System
Injection pump
Injection pump pressure
Injection timing
Fuel requirement
Coolant capacity
Alternator output

2 - 8 Genie Z-45/22 Part No. 29487
Section 2 - Specifications Service Manual - First Edition
5 - 7 8 - 9
13 - 15 18 - 20
29 - 33 39 - 45
46 - 53 63 - 72
79 - 92 108 - 125
123 - 141 167 - 191
180 - 210 245 - 284
246 - 289 334 - 392
7 - 8 10 - 11
17 - 20 24 - 27
35 - 41 48 - 56
57 - 66 78 - 90
91 - 108 124 - 147
145 - 166 196 - 225
203 - 235 275 - 318
271 - 318 368 - 431
9 - 10 12 - 14
22 - 25 30 - 34
45 - 52 61 - 70
76 - 86 103 - 117
123 - 144 168 - 196
192 - 224 260 - 304
253 - 296 343 - 402
362 - 419 490 - 568
SPECIFICATIONS
Bolt torque specifications - continued
Size - Standard ft-lbs Nm
M-6
M-8
M-10
M-12
M-14
M-16
M-18
M-20
Size - Grade 7
M-6
M-8
M-10
M-12
M-14
M-16
M-18
M-20
Size - Grade 9
M-6
M-8
M-10
M-12
M-14
M-16
M-18
M-20