Genie Z-45/25 User manual

First Edition
Second Printing
Part No. 52709
Service Manual
From Serial number 9998 to 21179

Genie Z-45/25 & Genie Z-45/25J Part No. 52709
First Edition • Second Printing
ii
Introduction
®
Copyright © 1998 by Genie Industries
First Edition: Second Printing, September 2000
"Genie" and "Z" are Registered Trademarks
of Genie Industries in the USA and many other
countries.
These machines comply with
ANSI/SIA 92.5-1992.
Printed on recycled paper
Printed in U.S.A.
Important
Read, understand and obey the safety rules and
operating instructions in the
Genie Z-45/25 & Genie Z-45/25J Operator's
Manual before attempting any maintenance or
repair procedure.
This service manual covers the Genie Z-45/25 &
Genie Z-45/25J 2WD and 4WD models introduced
in 1998.
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 97030, Redmond WA
98073-9730 U.S.A.
If you have any questions, please call Genie
Industries.
Contact us:
http://www.genielift.com
e-mail: [email protected]

Part No. 52709 Genie Z-45/25 & Genie Z-45/25J
First Edition • Second Printing
iii
Safety Rules
Section 1 • Safety Rules
Danger
Failure to obey the instructions and safety rules in
this manual, and the Genie Z-45/25 &
Genie Z-45/25J Operator's Manual will result in
death or serious injury.
Many of the hazards identified in the operator's
manual are also safety hazards when maintenance
and repair procedures are performed.
Do Not Perform Maintenance
Unless:
You are trained and qualified to perform
maintenance on this machine.
You read, understand and obey:
- manufacturer’s instructions and safety rules
- employer’s safety rules and worksite
regulations
- applicable governmental regulations
You have the appropriate tools, lifting
equipment and a suitable workshop.

Genie Z-45/25 & Genie Z-45/25J Part No. 52709
First Edition • Second Printing
SAFETY RULES
iv
Section 1 • Safety Rules
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.
Red—used to indicate the
presence of an imminently
hazardous situation which, if not
avoided, will result in death or
serious injury.
Orange—used to indicate the
presence of a potentially
hazardous situation which, if not
avoided, could result in death or
serious injury.
Yellow with safety alert symbol—
used to indicate the presence of a
potentially hazardous situation
which, if not avoided, may cause
minor or moderate injury.
Yellow without safety alert
symbol—used to indicate the
presence of a potentially
hazardous situation which, if not
avoided, may result in property
damage.
Green—used to indicate 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 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.
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 .

Part No. 52709 Genie Z-45/25 & Genie Z-45/25J
First Edition • Second Printing
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 - 4
Ford LRG-425 EFI Engine Specifications ................................................................. 2 - 5
Deutz F3L 1011F Engine Specifications ................................................................... 2 - 7
Perkins 104-22 Engine Specifications....................................................................... 2 - 8
Hydraulic Hose and Fitting Torque Specifications ..................................................... 2 - 9
Section Three Theory of Operation
Power Source ........................................................................................................... 3 - 1
Hydraulic System ...................................................................................................... 3 - 1
Electrical System ...................................................................................................... 3 - 1
Limit Switches ........................................................................................................... 3 - 2
Machine Controls ...................................................................................................... 3 - 2

Genie Z-45/25 & Genie Z-45/25J Part No. 52709
First Edition • Second Printing
TABLE OF CONTENTS
vi
Section Four Scheduled Maintenance Procedures
Introduction ............................................................................................................... 4 - 1
Maintenance Inspection Report ................................................................................ 4 - 3
A-1 Inspect the Operator's and Safety Manuals .................................................... 4 - 5
A-2 Inspect the Decals and Placards ..................................................................... 4 - 5
A-3 Inspect for Damage and Loose or Missing Parts ............................................. 4 - 6
A-4 Check the Engine Oil Level ............................................................................. 4 - 7
A-5 Check the Engine Coolant Level - Liquid Cooled Models ................................ 4 - 8
A-6 Check for Fuel Leaks ...................................................................................... 4 - 8
A-7 Check the Hydraulic Oil Level ......................................................................... 4 - 9
A-8 Check for Hydraulic Leaks ............................................................................ 4 - 10
A-9 Check the Tire Pressure ............................................................................... 4 - 10
A-10 Test the Oscillate Axle (if equipped) .............................................................. 4 - 11
A-11 Test the Platform and Ground Controls ......................................................... 4 - 11
A-12 Test the Auxiliary Power Operation ............................................................... 4 - 12
A-13 Test the Tilt Sensor ....................................................................................... 4 - 13
A-14 Test the Limit Switches ................................................................................. 4 - 14
A-15 Check the Engine Belt - Perkins Diesel Models ............................................ 4 - 18
A-16 Inspect the Engine Air Filter Element ............................................................ 4 - 19
A-17 Replace the Fuel Filters - Ford Models ......................................................... 4 - 20
A-18 Inspect the Radiator - Perkins Models .......................................................... 4 - 21
A-19 Perform 30 Day Service ................................................................................ 4 - 22
A-20 Replace the Engine Oil and Filter - Ford and Perkins Diesel Models ............ 4 - 23
A-21 Inspect the Fuel Filter/Water Separator - Diesel Models ............................... 4 - 24
A-22 Check and Adjust the Engine RPM - Perkins Diesel Models ......................... 4 - 26
A-23 Check the Engine Belt - Ford Models ............................................................ 4 - 28

Part No. 52709 Genie Z-45/25 & Genie Z-45/25J
First Edition • Second Printing
TABLE OF CONTENTS
vii
Section Four Scheduled Maintenance Procedures, continued
B-1 Check the Battery ......................................................................................... 4 - 29
B-2 Inspect the Electrical Wiring .......................................................................... 4 - 29
B-3 Check the Radiator - Ford Models ................................................................ 4 - 30
B-4 Check the Exhaust System ........................................................................... 4 - 31
B-5 Check the Hydraulic Return Filter Condition Indicator ................................... 4 - 32
B-6 Check the Oil Cooler and Cooling Fins - Deutz Diesel Models ...................... 4 - 32
B-7 Inspect the Tires and Wheels (including lug nut torque) ................................ 4 - 33
B-8 Confirm the Proper Brake Configuration ....................................................... 4 - 34
B-9 Check the Oil Level in the Drive Hubs ........................................................... 4 - 34
B-10 Check and Adjust the Engine RPM - Ford and Deutz Diesel Models ............ 4 - 35
B-11 Test the Key Switch ...................................................................................... 4 - 37
B-12 Test the Emergency Stop Buttons ................................................................. 4 - 37
B-13 Test the Ground Control Override ................................................................. 4 - 38
B-14 Check the Directional Valve Linkage ............................................................. 4 - 38
B-15 Test the Platform Self-leveling ...................................................................... 4 - 39
B-16 Test the Horn ................................................................................................ 4 - 40
B-17 Test the Foot Switch ..................................................................................... 4 - 40
B-18 Test the Engine Idle Select ........................................................................... 4 - 41
B-19 Test the Fuel Select Operation - Ford Models ............................................... 4 - 42
B-20 Test the Drive Enable System ....................................................................... 4 - 43
B-21 Test the Drive Brakes ................................................................................... 4 - 44
B-22 Test the Drive Speed - Stowed Position ........................................................ 4 - 45
B-23 Test the Drive Speed - Raised or Extended Position .................................... 4 - 46

Genie Z-45/25 & Genie Z-45/25J Part No. 52709
First Edition • Second Printing
Section Four Scheduled Maintenance Procedures,continued
B-24 Test the Alarm Package - Optional Equipment.............................................. 4 - 47
B-25 Perform Hydraulic Oil Analysis ...................................................................... 4 - 48
B-26 Replace the Hydraulic Tank Return Filter...................................................... 4 - 48
B-27 Replace the Fuel Filter/Water Separator Element - Perkins Diesel Models ... 4 - 49
B-28 Replace the Fuel Filter Element - Perkins Diesel Models .............................. 4 - 51
B-29 Replace the Spark Plugs - Ford Models ........................................................ 4 - 52
B-30 Replace the Engine Air Filter Element ........................................................... 4 - 53
C-1 Check the Engine Belt- Deutz Diesel Models ................................................ 4 - 55
C-2 Replace the Engine Oil and Filter - Deutz Diesel Models .............................. 4 - 57
C-3 Check the Engine Valve Clearances - Deutz Diesel Models ......................... 4 - 57
C-4 Change or Recondition the Engine Coolant - Liquid Cooled Models ............. 4 - 58
C-5 Check the Engine Valve Clearances - Perkins Diesel Models....................... 4 - 59
C-6 Replace the PCV Valve - Ford Models .......................................................... 4 - 60
D-1 Check the Boom Wear Pads ......................................................................... 4 - 61
D-2 Check the Turntable Rotation Bearing Bolts ................................................. 4 - 62
D-3 Check the Free-wheel Configuration ............................................................. 4 - 63
D-4 Grease the Turntable Rotation Bearing and Rotate Gear.............................. 4 - 65
D-5 Replace the Drive Hub Oil............................................................................. 4 - 66
D-6 Replace the Drive Loop Hydraulic Filter ........................................................ 4 - 67
D-7 Check and Adjust the Air/LPG Mixture - Ford Models ................................... 4 - 68
D-8 Replace the Diesel Fuel Filter/Water Separator - Deutz Diesel Models......... 4 - 69
viii
TABLE OF CONTENTS

Part No. 52709 Genie Z-45/25 & Genie Z-45/25J
First Edition • Second Printing
Section Four Scheduled Maintenance Procedures,continued
E-1 Test or Replace the Hydraulic Oil.................................................................. 4 - 70
E-2 Change or Recondition the Engine Coolant - Ford Models ........................... 4 - 72
E-3 Change the Fuel Hoses ................................................................................ 4 - 74
E-4 Check the Toothed Belt - Deutz Diesel Models ............................................. 4 - 77
E-5 Check the Engine Valve Clearance - Ford Models ........................................ 4 - 77
E-6 Check the Engine Cylinder Compression - Ford Models ............................... 4 - 77
E-7 Check the Fuel Injection Pumps and Injectors - Deutz Diesel Models........... 4 - 77
E-8 Replace the Timing Belt - Ford Models ......................................................... 4 - 77
E-9 Grease the Steer Axle Wheel Bearings, 2WD Models .................................. 4 - 78
Section Five Troubleshooting Flow Charts
Introduction ............................................................................................................... 5 - 1
Fault Codes .............................................................................................................. 5 - 3
1 Engine Will Not Crank Over ............................................................................ 5 - 6
2 Engine Cranks Over But Will Not Start - Ford Models ..................................... 5 - 8
2A Engine Runs While Cranking Then Dies ....................................................... 5 - 10
3 Engine Cranks Over But Will Not Start - Diesel Models ................................ 5 - 11
4 Engine Will Not Start On LPG, But Will Start On Gasoline - Ford Models ..... 5 - 14
5 Engine Will Not Start On Gasoline, But Will Start On LPG - Ford Models ..... 5 - 16
6 Engine High Idle Inoperative - Ford Models .................................................. 5 - 17
7 Engine Low Idle Inoperative - Ford Models ................................................... 5 - 18
8 Engine High Idle Inoperative - Diesel Models ................................................ 5 - 19
9 Engine Low Idle Inoperative - Diesel Models................................................. 5 - 21
10 All Functions Inoperative, Engine Starts and Runs ....................................... 5 - 22
11 All Lift and Steer Functions Inoperative, Drive Functions Operational ........... 5 - 23
ix
TABLE OF CONTENTS

Genie Z-45/25 & Genie Z-45/25J Part No. 52709
First Edition • Second Printing
TABLE OF CONTENTS
Section Five Troubleshooting Flow Charts, continued
12 Ground Controls Inoperative, Platform Controls Operate Normally ............... 5 - 24
13 Platform Controls Inoperative, Ground Controls Operate Normally ............... 5 - 25
14 Primary Boom Up Function Inoperative ........................................................ 5 - 26
15 Primary Boom Down Function Inoperative (before serial number 13099) ..... 5 - 29
16 Primary Boom Down Function Inoperative (after serial number 13098) ........ 5 - 32
17 Secondary Boom Up Function Inoperative .................................................... 5 - 35
18 Secondary Boom Down Function Inoperative ............................................... 5 - 38
19 Primary Boom Extend Function Inoperative .................................................. 5 - 41
20 Primary Boom Retract Function Inoperative.................................................. 5 - 43
21 Turntable Rotate Left Function Inoperative ................................................... 5 - 45
22 Turntable Rotate Right Function Inoperative ................................................. 5 - 49
23 All Platform Leveling Functions Inoperative .................................................. 5 - 53
24 Platform Level Up Function Inoperative ........................................................ 5 - 54
25 Platform Level Down Function Inoperative .................................................... 5 - 56
26 Platform Rotate Left Function Inoperative ..................................................... 5 - 58
27 Platform Rotate Right Function Inoperative ................................................... 5 - 61
28 Jib Boom Up Function Inoperative, Z-45/25J Models .................................... 5 - 64
29 Jib Boom Down Function Inoperative, Z-45/25J Models ............................... 5 - 66
30 Steer Left Function Inoperative ..................................................................... 5 - 68
31 Steer Right Function Inoperative ................................................................... 5 - 69
32 Oscillate Function Inoperative ....................................................................... 5 - 70
33 All Drive Functions Inoperative, All Other Functions Operate Normally ......... 5 - 71
34 Drive Forward Or Reverse Function Inoperative ........................................... 5 - 74
35 Traction Function Inoperative ........................................................................ 5 - 75
36 Machine Will Not Drive At Full Speed ............................................................ 5 - 76
37 Machine Drives At Full Speed With Platform Raised or Extended ................. 5 - 77
38 Drive Enable System Is Malfunctioning ......................................................... 5 - 78
39 Auxiliary Functions Inoperative ..................................................................... 5 - 79
x

Part No. 52709 Genie Z-45/25 & Genie Z-45/25J
First Edition • Second Printing
TABLE OF CONTENTS
Section Six Schematics
Introduction ............................................................................................................... 6 - 1
Electrical Components .............................................................................................. 6 - 2
Electrical Symbols Legend ....................................................................................... 6 - 4
Abbreviation Legend ................................................................................................. 6 - 5
Ford LRG-425 EFI Engine Harness (before serial number 13099) ........................... 6 - 7
Ford LRG-425 EFI Engine Harness (after serial number 13098) .............................. 6 - 8
Electrical Schematic - Z-45/25 Ford Models (before serial number 13099)............. 6 - 10
Ground Control Box Wiring Diagram, Z-45/25 Ford Models
(before serial number 13099) ............................................................................. 6 - 11
Platform Control Box Wiring Diagram, Z-45/25 Ford Models
(before serial number 13099) ............................................................................. 6 - 12
Electrical Schematic, Z-45/25 Ford Models
(from serial number 13098 to 16303) ................................................................. 6 - 14
Ground Control Box Wiring Diagram, Z-45/25 Ford Models
(from serial number 13098 to 16303) ................................................................. 6 - 15
Platform Control Box Wiring Diagram, Z-45/25 Ford Models
(from serial number 13098 to 16303) ................................................................. 6 - 16
Electrical Schematic, Z-45/25J Ford Models
(before serial number 13099) ............................................................................. 6 - 18
Ground Control Box Wiring Diagram, Z-45/25J Ford Models
(before serial number 13099) ............................................................................. 6 - 19
Platform Control Box Wiring Diagram, Z-45/25J Ford Models
(before serial number 13099) ............................................................................. 6 - 20
Electrical Schematic, Z-45/25J Ford Models
(from serial number 13098 to 16303) ................................................................. 6 - 22
Ground Control Box Wiring Diagram, Z-45/25J Ford Models
(from serial number 13098 to 16303) ................................................................. 6 - 23
xi

Genie Z-45/25 & Genie Z-45/25J Part No. 52709
First Edition • Second Printing
TABLE OF CONTENTS
xii
Section Six Schematics, continued
Platform Control Box Wiring Diagram, Z-45/25J Ford Models
(from serial number 13098 to 16303) ................................................................. 6 - 24
Electrical Schematic, Z-45/25 Ford Models (after serial number 16303) ................. 6 - 26
Ground Control Box Wiring Diagram, Z-45/25 Ford Models
(after serial number 16303) ................................................................................ 6 - 27
Platform Control Box Wiring Diagram, Z-45/25 Ford Models
(after serial number 16303) ................................................................................ 6 - 28
Electrical Schematic, Z-45/25J Ford Models (after serial number 16303) ............... 6 - 30
Ground Control Box Wiring Diagram, Z-45/25J Ford Models
(after serial number 16303) ................................................................................ 6 - 31
Platform Control Box Wiring Diagram, Z-45/25J Ford Models
(after serial number 16303) ................................................................................ 6 - 32
Electrical Schematic, Z-45/25 Deutz Models (before serial number 13099) ............ 6 - 34
Ground Control Box Wiring Diagram, Z-45/25 Deutz Models
(before serial number 13099) ............................................................................. 6 - 35
Platform Control Box Wiring Diagram, Z-45/25 Deutz Models
(before serial number 13099) ............................................................................. 6 - 36
Electrical Schematic, Z-45/25 Deutz Models
(from serial number 13098 to 16303) ................................................................. 6 - 38
Ground Control Box Wiring Diagram, Z-45/25 Deutz Models
(from serial number 13098 to 16303) ................................................................. 6 - 39
Platform Control Box Wiring Diagram, Z-45/25 Deutz Models
(from serial number 13098 to 16303) ................................................................. 6 - 40
Electrical Schematic, Z-45/25J Deutz Models (before serial number 13099) .......... 6 - 42
Ground Control Box Wiring Diagram, Z-45/25J Deutz Models
(before serial number 13099) ............................................................................. 6 - 43
Platform Control Box Wiring Diagram, Z-45/25J Deutz Models
(before serial number 13099) ............................................................................. 6 - 44
Electrical Schematic, Z-45/25J Deutz Models
(from serial number 13098 to 16303) ................................................................. 6 - 46
Ground Control Box Wiring Diagram, Z-45/25J Deutz Models
(from serial number 13098 to 16303) ................................................................. 6 - 47

Part No. 52709 Genie Z-45/25 & Genie Z-45/25J
First Edition • Second Printing
TABLE OF CONTENTS
xiii
Section Six Schematics, continued
Platform Control Box Wiring Diagram, Z-45/25J Deutz Models
(from serial number 13098 to 16303) ................................................................. 6 - 48
Platform Control Box Wiring Diagram - Lift Drive Select Option,
Z-45/25J Deutz Models (from serial number 13098 to 16303) ................................ 6 - 49
Electrical Schematic, Z-45/25 Deutz Models
(after serial number 16303) ................................................................................ 6 - 51
Ground Control Box Wiring Diagram, Z-45/25 Deutz Models
(after serial number 16303) ................................................................................ 6 - 52
Platform Control Box Wiring Diagram, Z-45/25 Deutz Models
(after serial number 16303) ................................................................................ 6 - 53
Platform Control Box Wiring Diagram - Lift Drive Select Option,
Z-45/25 Deutz Models (after serial number 16303) ................................................. 6 - 54
Electrical Schematic, Z-45/25J Deutz Models (after serial number 16303) ............. 6 - 56
Ground Control Box Wiring Diagram, Z-45/25J Deutz Models
(after serial number 16303) ................................................................................ 6 - 57
Platform Control Box Wiring Diagram, Z-45/25J Deutz Models
(after serial number 16303) ................................................................................ 6 - 58
Platform Control Box Wiring Diagram - Lift Drive Select Option,
Z-45/25J Deutz Models (after serial number 16303) ............................................... 6 - 59
Electrical Schematic, Z-45/25 Perkins Models (before serial number 16304) ......... 6 - 61
Ground Control Box Wiring Diagram, Z-45/25 Perkins Models
(before serial number 16304) ............................................................................. 6 - 62
Platform Control Box Wiring Diagram, Z-45/25 Perkins Models
(before serial number 16304) ............................................................................. 6 - 63
Electrical Schematic, Z-45/25J Perkins Models (before serial number 16304) ....... 6 - 65
Ground Control Box Wiring Diagram, Z-45/25J Perkins Models
(before serial number 16304) ............................................................................. 6 - 66

Genie Z-45/25 & Genie Z-45/25J Part No. 52709
First Edition • Second Printing
TABLE OF CONTENTS
Section Six Schematics, continued
Platform Control Box Wiring Diagram, Z-45/25J Perkins Models
(before serial number 16304) ............................................................................. 6 - 67
Platform Control Box Wiring Diagram - Lift/Drive Select Option,
Z-45/25J Perkins Models (before serial number 16304) ......................................... 6 - 68
Electrical Schematic, Z-45/25 Perkins Models (after serial number 16303) ............ 6 - 70
Ground Control Box Wiring Diagram, Z-45/25 Perkins Models
(after serial number 16303) ................................................................................ 6 - 71
Platform Control Box Wiring Diagram, Z-45/25 Perkins Models
(after serial number 16303) ................................................................................ 6 - 72
Electrical Schematic, Z-45/25J Perkins Models (after serial number 16303)) ......... 6 - 74
Ground Control Box Wiring Diagram, Z-45/25J Perkins Models
(after serial number 16303) ................................................................................ 6 - 75
Platform Control Box Wiring Diagram, Z-45/25J Perkins Models
(after serial number 16303) ................................................................................ 6 - 76
Platform Control Box Wiring Diagram - Lift/Drive Select Option,
Z-45/25J Perkins Models (after serial number 16303) ............................................ 6 - 78
Platform Control Box Wiring Diagram- Load Sensor Option, All Models ................. 6 - 79
Hydraulic Symbols Legend ..................................................................................... 6 - 80
2WD Hydraulic Schematic ...................................................................................... 6 - 82
4WD Hydraulic Schematic ...................................................................................... 6 - 83
Section Seven Repair Procedures
Introduction ............................................................................................................... 7 - 1
Platform Controls
1-1 Joystick Controllers ......................................................................................... 7 - 2
1-2 Horsepower Limiter Board .............................................................................. 7 - 8
xiv

Part No. 52709 Genie Z-45/25 & Genie Z-45/25J
First Edition • Second Printing
Section Seven Repair Procedures, continued
1-3 Foot Switch ................................................................................................... 7 - 10
1-4 Toggle Switches ............................................................................................ 7 - 11
Platform Components
2-1 Platform ........................................................................................................ 7 - 13
2-2 Platform Leveling Slave Cylinder .................................................................. 7 - 14
2-3 Platform Rotator ............................................................................................ 7 - 15
Jib Boom Components, Z-45/25J Models
3-1 Jib Boom, Z-45/25J Models .......................................................................... 7 - 18
3-2 Jib Boom Lift Cylinder, Z-45/25J Models ....................................................... 7 - 19
3-3 Jib Boom / Platform Rotate Manifold Components, Z-45/25J Models ........... 7 - 21
Primary Boom Components
4-1 Plastic Cable Track ....................................................................................... 7 - 22
4-2 Primary Boom ............................................................................................... 7 - 27
4-3 Primary Boom Lift Cylinder ........................................................................... 7 - 30
4-4 Primary Boom Extension Cylinder ................................................................. 7 - 31
4-5 Platform Leveling Master Cylinder ................................................................ 7 - 32
Secondary Boom Components
5-1 Secondary Boom .......................................................................................... 7 - 34
5-2 Secondary Boom Lift Cylinders ..................................................................... 7 - 39
Turntable Covers
6-1 Turntable Covers .......................................................................................... 7 - 40
Deutz Engine F3L 1011F
7-1 RPM Adjustment ........................................................................................... 7 - 41
7-2 Flex Plate ...................................................................................................... 7 - 41
7-3 Oil Temperature and Oil Pressure Gauges ................................................... 7 - 42
xv
TABLE OF CONTENTS

Genie Z-45/25 & Genie Z-45/25J Part No. 52709
First Edition • Second Printing
Section Seven Repair Procedures, continued
Perkins 104-22 Engine
8-1 RPM Adjustment ........................................................................................... 7 - 43
8-2 Flex Plate ...................................................................................................... 7 - 43
8-3 Coolant Temperature and Oil Pressure Gauages ......................................... 7 - 44
Ford LRG-425 EFI Engine
9-1 Timing Adjustment ........................................................................................ 7 - 45
9-2 RPM Adjustment ........................................................................................... 7 - 45
9-3 Flex Plate ...................................................................................................... 7 - 45
9-4 Water Temperature and Oil Pressure Gauges .............................................. 7 - 46
Ground Controls
10-1 Control Relays .............................................................................................. 7 - 48
10-2 Toggle Switches, See 1-4, Toggle Switches ................................................. 7 - 49
10-3 Wago®Components ...................................................................................... 7 - 49
10-4 Engine Fault Codes - Ford Models ................................................................ 7 - 50
Hydraulic Pumps
11-1 Lift/Steer Pump ............................................................................................. 7 - 52
11-2 Drive Pump ................................................................................................... 7 - 53
Manifolds
12-1 Function Manifold Components ..................................................................... 7 - 56
12-2 Valve Adjustments - Function Manifold ......................................................... 7 - 62
12-3 Turntable Rotation Manifold Components ..................................................... 7 - 63
12-4 Directional Valve Manifold Components ........................................................ 7 - 65
12-5 2WD Drive Manifold Components ................................................................. 7 - 68
12-6 Valve Adjustments, 2WD Drive Manifold ....................................................... 7 - 70
12-7 4WD Drive Manifold Components ................................................................. 7 - 72
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Part No. 52709 Genie Z-45/25 & Genie Z-45/25J
First Edition • Second Printing
Section Seven Repair Procedures, continued
12-8 Valve Adjustments, 4WD Drive Manifold ....................................................... 7 - 76
.Fuel and Hydraulic Tanks
13-1 Fuel Tank ...................................................................................................... 7 - 77
13-2 Hydraulic Tank .............................................................................................. 7 - 80
Turntable Rotation Components
14-1 Rotation Hydraulic Motor ............................................................................... 7 - 80
2WD Steering Axle Components
15-1 Yoke and Hub ............................................................................................... 7 - 84
15-2 Steering Cylinders ......................................................................................... 7 - 84
15-3 Tie Rod ......................................................................................................... 7 - 85
4WD Steering Axle Components
16-1 Yoke and Hub ............................................................................................... 7 - 86
16-2 Steering Cylinders, See 15-2, Steering Cylinders ......................................... 7 - 88
16-3 Tie Rod, See 15-3, Tie Rod .......................................................................... 7 - 88
Oscillating Axle Components
17-1 Oscillating Axle Lock-out Cylinders ............................................................... 7 - 89
Non-steering Axle Components
18-1 Drive Motor ................................................................................................... 7 - 90
18-2 Drive Hub ...................................................................................................... 7 - 91
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TABLE OF CONTENTS

Genie Z-45/25 & Genie Z-45/25J Part No. 52709
First Edition • Second Printing
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Part No. 52709 Genie Z-45/25 & Genie Z-45/25J 2 - 1
Section 2 • SpecificationsFirst Edition • Second Printing
Specifications
Machine Specifications
Stowed dimensions Z-45/25 Z-45/25J
(non jib) (jib)
Length 18 ft 22 ft 3 in
5.5 m 6.8 m
Width
Standard Base Models 7 ft 4 in 7 ft 4 in
2.2 m 2.2 m
Narrow Base Models 5 ft 9 in 5 ft 9 in
1.8 m 1.8 m
Height
Standard Base Models 6 ft 10 in 6 ft 10 in
2.1 m 2.1 m
Narrow Base Models 6 ft 7 in 6 ft 7 in
2.05 m 2.05 m
Weight
Standard Base Models 14,000 lbs 14,700 lbs
6350 kg 6668 kg
Narrow Base Models 17,100 lbs 17,100 lbs
7756 kg 7756 kg
Ground clearance
Standard Base Models 10 in 10 in
25.4 cm 25.4 cm
Narrow Base Models 7 in 7 in
17.7 cm 17.7 cm
Operational dimensions
Maximum platform height
Standard Base Models 45 ft 8 in 45 ft 6 in
13.9 m 13.8 m
Narrow Base Models 45 ft 5 in 45 ft 5 in
13.9 m 13.9 m
Maximum horizontal reach 124 ft 6 in 25 ft 3 in
17.5 m 7.7 m
Maximum turntable tailswing 0 in 0 in
0 cm 0 cm
Wheelbase 6 ft 8 in 6 ft 8 in
2 m 2 m
1Outreach specification with platform rotated
90 degrees.
Z-45/25 Z-45/25J
(non jib) (jib)
Minimum turning radius, inside
Standard Base Models 4 ft 6 in 4 ft 6 in
1.4 m 1.4 m
Narrow Base Models 5 ft 5 ft
1.5 m 1.5 m
Minimum turning radius, outside
Standard Base Models 11 ft 6 in 11 ft 6 in
3.5 m 3.5 m
Narrow Base Models 11 ft 11 ft
3.35 m 3.35 m
Turntable rotation 359° 359°
Platform rotation 180° 160°
Maximum capacity 500 lbs 500 lbs
6 foot platform 227 kg 227 kg
Maximum allowable
side force (ANSI and CSA) 150 lbs 150 lbs
68 kg 68 kg
Platform dimensions
Length 72 in
183 cm
Width 30 in
76 cm

2 - 2 Genie Z-45/25 & Genie Z-45/25J Part No. 52709
Section 2 • Specifications First Edition • Second Printing
SPECIFICATIONS
Tires and wheels Rough terrain Industrial
Wheel diameter 17.5 inches 14.5 inches
Wheel width 10.5 inches 7 inches
Wheel lugs, 4WD 9 @ 5/8 -18
Wheel lugs, 2WD
Front 8 @ 5/8-18 8 @ 5/8-18
Rear 9 @ 5/8-18 9 @ 5/8-18
Lug nut torque 125 ft-lbs 125 ft-lbs
169.5 Nm 169.5 Nm
Tire size 14-17.5 NHS 9-14.5 LT
Tire ply rating 14 Tread 8
Sidewall 6
Tire contact area 59 sq in 43.5 sq in
149.9 sq cm 280 sq cm
Overall tire diameter 35.8 in 28 in
90.9 cm 71 cm
Tire pressure 45 psi Foam filled
2.76 bar
Fluid capacities
Fuel tank 17 gallons
64.3 liters
LPG tank 33.5 pounds
15.2 kg
Hydraulic tank 24 gallons
91 liters
Hydraulic system 30 gallons
(including tank) 113.6 liters
Drive torque hubs 17 fl oz
0.51 liters
Continuous improvement of our products is a Genie
policy. Product specifications are subject to change
without notice.
Performance Specifications
Drive speeds, maximum
Drive speed, stowed 4.8 mph
All models 7.7 km/h
40 ft/5.7 sec
12.2 m/5.7 sec
Drive speed, boom 0.6 mph
raised or extended, 1 km/h
Standard Base Models 40 ft/45 sec
12.2 m/45 sec
Drive speed, boom 0.36 mph
raised or extended, 0.58 km/h
Narrow Base Models 40 ft/79 sec
12.2 m/79 sec
Gradeability 2WD 4WD
Boom Stowed Position 30% 45%