Genie Z45/25J Operating manual

Self-Propelled Servicing Platform Part No. 107713
July 2011
2
Contact Us:
http://www.genieindustries.com
e-mail: [email protected]
Copyright © 2004 by Genie Industries
107713 Rev B July 2011
First Edition, Second 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.
Service Manual Supplement

Self-Propelled Servicing Platform Part No. 107713
November 2011
2
Contact Us:
http://www.genielift.com
e-mail: [email protected]
Copyright © 2011 Terex Corporation
107713 Rev B July 2011
First Edition, Second Printing
"Genie" and "Z" are registered trademarks of
Terex South Dakota, Inc. in the USA and many
other countries.
Printed on recycled paper
Printed in U.S.A.
Service Manual Supplement

Part No. 107713 Self-Propelled Servicing Platform
Service Manual Supplement
July 2011
3
Table of Contents
Machine Specifications ................................................. 4
Scheduled Maintenance Procedure ............................ 9
Maintenance Inspection Report ................................. 10
Maintenance Procedure ............................................. 11
Repair Procedures ..................................................... 16
Steer Axle Components ............................................. 17
Non-steer Axle Components ...................................... 21
Fiberglass Covers ...................................................... 23
Electrical Schematic ................................................... 25
Ground Control Box Terminal Strip Wiring Diagram .. 27
Ground Control Box Switch Panel Wiring Diagram ... 28
Platform Control Box Wiring Diagram ........................ 29
Platform Control Box Switch Panel Wiring Diagram .. 30
Engine Panel Diagram ............................................... 31
Power Cable Diagram ................................................ 32
Hydraulic Schematic .................................................. 33

Self-Propelled Servicing Platform Part No. 107713
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Specifications
Machine Specifications
Tires and wheels
Tire size 9-14.5 LT
Wheel diameter 14.5 inches
Wheel width 7 inches
Wheel lugs
Front 8 @ 5/8-18
Rear 9 @ 5/8-18
Lug nut torque 125 ft-lbs
169.5 Nm
Tire size 9-14.5 LT
Tire ply rating Tread 6
Sidewall 6
Tire contact area 43.5 sq in
280 sq cm
Overall tire diameter 28 in
71 cm
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 23 fl oz
0.68 liter
For operational specifications, refer to the
Operator's Manual.
Continuous improvement of our products is a
Genie policy. Product specifications are
subject to change without notice.
Performance Specifications
Gradeability (boom stowed) 30%
Boom function speeds, maximum
from platform controls
Jib boom up 35 to 41 seconds
Jib boom down 18 to 24 seconds
Primary boom up 47 to 53 seconds
Primary boom down 34 to 40 seconds
Secondary boom up 35 to 41 seconds
Secondary boom down 22 to 28 seconds
Primary boom extend 7 to 13 seconds
Primary boom retract 9 to 15 seconds
Turntable rotate, 357° 94 to 100 seconds
primary boom retracted
Platform rotate, 160° 3 to 9 seconds
Platform level up 199 to 205 seconds
Platform level down 127 to 133 seconds
REV A
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Part No. 107713 Self-Propelled Servicing Platform
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Hydraulic Specifications
Hydraulic Oil Specifications
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
Mineral based Shell Tellus T32
Shell Tellus T46
Chevron Aviation A
Note: Genie specifications require additional
equipment and special installation instructions for
the approved optional fluids. Consult the Genie
Industries Service Department before use.
Function pump
Type: fixed displacement gear pump
Displacement 0.12 cu in
2 cc
Hydraulic tank circuit 10 micron with
return line filter 25 psi / 1.7 bar bypass
Function manifold
Function relief valve pressure 3200 psi
220.6 bar
Secondary boom down 2000 psi
relief valve pressure 138 bar
Auxiliary pump
Type: fixed displacement gear pump
Displacement 0.5 gallons per minute
1.9 liters per minute
Auxiliary pump 3200 psi
relief pressure 220.6 bar
SPECIFICATIONSREV A

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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 intermittent 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
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.
Injection system
Injection pump make Bocsh MD
Injection timing 21° BTDC
Injection pump pressure 1991 psi
137 bar
Fuel requirement diesel number 2-D
Alternator
Output 12V, 150 watts
Starter motor
Brush length, new 0.5188 in
13 mm
Brush length, minimum 0.3346 in
8.5 mm
Battery
Type 12V, Group 70
Quantity 1
Cold cranking ampere 450A
Reserve capacity @ 25A rate 125 minutes
Fan belt deflection 1/4to 3/8 inch
7 to 9 mm
SPECIFICATIONS REV A
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Part No. 107713 Self-Propelled Servicing Platform
Service Manual Supplement
January 2006
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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
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
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
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.
Note: 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.
SPECIFICATIONSREV A

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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.
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.
Used to indicate the presence of a
potentially hazardous situation
which, if not avoided, may cause
minor or moderate injury.
Used to indicate the presence of a
potentially hazardous situation
which, if not avoided, may result in
property damage.
Indicates that a specific result is expected after
performing a series of steps.
Scheduled Maintenance Procedure
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, 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.
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-steering wheels
• Turntable secured with the turntable
rotation lock
• Key switch in the off position with the key
removed
• Wheels chocked

Self-Propelled Servicing Platform Part No. 107713
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Maintenance Inspection Report
Instructions
• Make copies of this report to use for
each inspection. Maintain completed
forms for a minimum of 4 years or in
compliance with employer, jobsite
and governmental regulations and
requirements.
• If any inspection receives an “N”, tag
and remove the machine from
service, repair and reinspect it. After
repair, place a check in the “R” box.
Legend
Y = yes, acceptable
N = no, remove from service
R = repaired
Comments
Model
Serial number
Date
Hour meter
Machine owner
Inspected by (print)
Inspector signature
Inspector title
Inspector company
Checklist D Y N R
D-6.1 Temperature sensor
Refer to the Genie Z-45/25 Bi-Energy & Z-45/25J Bi-Energy Service
Manual for scheduled machine maintenance procedures.
The following scheduled maintenance procedure will need to be
performed every 1000 hours or annually in addition to regularly
scheduled machine maintenance inspections as outlined in the
Service Manual.
Service Manual Supplement

Part No. 107713 Self-Propelled Servicing Platform
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D-6.1
Test the Exhaust Manifold
Temperature Sensor
Note: Genie specifications require that this
procedure be performed every 1000 hours of
operation or yearly.
Yearly calibration of the exhaust manifold
temperature sensor is essential to safe machine
operation. Continued use of an improperly
calibrated temperature sensor could result in
failure to sense an accurate exhaust manifold
temperature. This could create a hazardous
situation.
Component damage hazard. This
procedure requires specific repair
skills and testing equipment.
Dealer service is strongly
recommended.
1 See How to Program the Temperature Display
and access the TYPE menu item.
2 To change the input type, press the
blank (unmarked) button to scroll through the
available choices until LIN is shown on the
display. Press the SEL button to select and
return to the main menu.
3 Press the SEL button until the OFSET menu is
shown on the display. Change the offset value
to zero.
4 Press and hold the SEL button for 3 seconds to
enter the value and return to the main menu.
Maintenance Procedure
5 Remove the jumper wire from the back of the
temperature display.
Result: The display will show SAVE to indicate the
programming changes are being saved into
memory.
Note: Do not turn the machine off before removing
the jumper from the back of the display. If the
machine is turned off before the jumper wire is
removed, all data may not save completely or
correctly. This could result in a fault display of FR IL
the next time the machine is turned on.
6 Use a precision DC voltage power supply with
an output range of -10 mV DC to 60 mV DC
and an accuracy of 0.03% or better. Connect
the negative lead to the TC - terminal and the
positive lead to the TC+ terminal of the
temperature display.
7 Set the power supply to mV DC and turn the
power supply on.
8 Compare the voltage on the temperature
display to that of the power supply over a range
of -10 mV DC to 60 mV DC.
Result: If the voltage differences between the
temperature display and the power supply are
within 0.02 mV DC at all points over the range
of -10 mV DC to 60 mV DC, the display does
not need to be calibrated.
Result: If the voltage differences between the
temperature display and the power supply are
more than 0.02 mV DC at one or more points
over the range of -10 mV DC to 60 mV DC, the
display will need to be calibrated. See How to
Calibrate the Temperature Sensor Voltage
Input.
REV B

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MAINTENANCE PROCEDURE
How to Program the
Temperature Display
There are six items that can be accessed in the
programming mode.
TYPE - Allows the choice of thermocouple being
used. Genie uses Type K thermocouples.
CJC - Cold Junction Compensation. This feature is
not used on your machine.
DISP - Allows the choice between °F or °C. Also
allows the choice between whole numbers or
tenths.
FLTER - Used to help stabilize the display if it is
difficult to read due to small process variations or
noise. Choose "0" for no filtering or up to "3" for
heavy filtering.
RANGE - The range value determines if the filter
will be applied to the new input sample. If the new
input value is within the range of the previous
display, the filter will be applied to the new input.
OFSET - Used to add or subtract a constant
temperature from the display.
1 Push in the red Emergency Stop buttons to the
off position at both the ground and platform
controls.
2 Open the ground control box and locate the
temperature display.
3 Connect a jumper wire between the PROGRAM
and COMM terminals on the back of the
temperature display.
4 Turn the key switch to ground control and pull
out the red Emergency Stop button to the on
position at the ground controls.
5 Press the SEL button to scroll to the menu item
you want to program.
6 Press the blank (unmarked) button to cycle
through available choices for each menu item.
7 Press the SEL button to make your choice and
return to the main menu.
8 Repeat steps 5 through 7 for each menu item.
9 Remove the jumper wire from the back of the
temperature display.
Result: The display will show SAVE to indicate
the programming changes are being saved into
memory.
Note: Do not turn the machine off before removing
the jumper from the back of the display. If the
machine is turned off before the jumper wire is
removed, all data may not save completely or
correctly. This could result in a fault display of FR IL
the next time the machine is turned on.
REV B
Service Manual Supplement

Part No. 107713 Self-Propelled Servicing Platform
Service Manual Supplement
July 2011
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MAINTENANCE PROCEDURE
How to Calibrate the
Temperature Sensor Voltage
Input
Component damage hazard. This
procedure requires specific repair
skills and testing equipment.
Dealer service is strongly
recommended.
Note: Calibration of the exhaust manifold
temperature sensor should only be performed by
individuals experienced in calibrating electronic
equipment.
Note: Allow the temperature sensor to warm up for
30 minutes before performing the calibration
procedure.
Note: The calibration procedure should be
performed at an ambient temperature between 59°
to 95° F / 15° to 35° C.
1 Push in the red Emergency Stop buttons to the
off position at both the ground and platform
controls.
2 Open the ground control box and locate the
temperature display.
3 Connect a jumper wire between the PROGRAM and
COMM terminals on the back of the temperature
display.
4 Tag and disconnect the thermocouple wires from
the TC + and TC - terminals of the temperature
display.
5 Use a precision DC voltage power supply with
an output range of -10 mV DC to 60 mV DC and
an accuracy of 0.03% or better. Connect the
positive and negative leads of the power supply
to the TC + and TC - terminals on the back the
temperature display.
6 Turn the key switch to ground control and pull
out the red Emergency Stop button to the on
position at the ground controls.
7 Turn on the power supply and set it to
-10 mV DC.
8 Press the SEL button until CAL is shown on the
display.
9 Press the blank (unmarked) button to
select YES.
Result: The display will show "00000".
10 Press the blank (unmarked) button to increment
the access code until the display shows
"00006".
11 Press and hold the SEL button. After entering the
correct access code, the display will show IN 1.
Follow the table below for the calibration
sequence.
Note: The display will show CALC for approximately 3
seconds after pressing the SEL button before
proceeding to the next input point.
Note: After the calibration sequence is complete,
the display will show CAL.
REV B

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MAINTENANCE PROCEDURE REV B
Service Manual Supplement
Display Parameter Action
IN1 -10mV DC Apply -10mV DC, wait 5 seconds, press SEL button
IN2 0 mV DC Apply 0 mV DC, wait 5 seconds, press SEL button.
IN3 10 mV DC Apply 10 mV DC, wait 5 seconds, press SEL button.
IN4 20 mV DC Apply 20 mV DC, wait 5 seconds, press SEL button.
IN5 30 mV DC Apply 30 mV DC, wait 5 seconds, press SEL button.
IN6 40 mV DC Apply 40 mV DC, wait 5 seconds, press SEL button.
IN5 50 mV DC Apply 50 mV DC, wait 5 seconds, press SEL button.
IN5 60 mV DC Apply 60 mV DC, wait 5 seconds, press SEL button.
12 Exit the programming mode by removing the
jumper wire from the back of the temperature
display.
Result: The display will show SAVE to indicate the
programming changes are being saved into
memory.
Note: Do not turn the machine off before removing
the jumper from the back of the display. If the
machine is turned off before the jumper wire is
removed, all data may not save completely or
correctly. This could result in a fault display of FR IL
the next time the machine is turned on.
13 Perform procedure Test the Exhaust Manifold
Temperature Display to verify voltage calibration.
14 Repeat the calibration procedure if necessary.

Part No. 107713 Self-Propelled Servicing Platform
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MAINTENANCE PROCEDUREREV B
How to Program the Temperature
Offset
Note: This procedure will only need to be performed
if the temperature display is being replaced or if the
saved data is corrupted and needs to be reset.
Note: Genie programs a default value of +30° F / -
1.1° C for temperature offset.
1 See How to Program the Temperature Display
and access the OFSET menu item.
2 To enter the offset value, press the
blank (unmarked) button to increment the
flashing digit or the sign of the number. To select
a new digit or sign of the number, press the SEL
button.
Note: If no digits are flashing, press the blank button
to toggle the sign of the number or press the SEL
button to wrap around to the LSD.
3 After the desired offset value is on the display,
press and hold the SEL button for 3 seconds to
enter the value and return to the main menu.
4 Remove the jumper wire from the back of the
temperature display.
Result: The display will show SAVE to indicate the
programming changes are being saved into
memory.
Note: Do not turn the machine off before removing
the jumper from the back of the display. If the
machine is turned off before the jumper wire is
removed, all data may not save completely or
correctly. This could result in a fault display of FR IL
the next time the machine is turned on.

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Part No. 107713 Self-Propelled Servicing Platform
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REV B Repair Procedures
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 & Genie Z-45/25J
Bi-Energy Operator’s Manual on your machine.
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 the 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
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.
Perform disassembly procedures to the point where
repairs can be completed. Then to
reassemble, 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.
Used to indicate the presence of a
potentially hazardous situation
which, if not avoided, may cause
minor or moderate injury.
Used to indicate the presence of a
potentially hazardous situation
which, if not avoided, may result in
property damage.
Indicates that a specific result is expected after
performing a series of steps.

Self-Propelled Servicing Platform Part No. 107713
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2 Loosen the wheel lug nuts. Do not remove them.
3 Block the non-steer wheels, and then center a
lifting jack of ample capacity under the steer
axle.
4 Raise the machine 6 inches / 15 cm and place
blocks under the chassis for support.
5 Remove the lug nuts. Remove the tire and
wheel assembly.
6 Remove the pin retaining fasteners from the
yoke pivot pins. Do not remove the pins.
7 Support and secure the yoke/hub assembly to a
lifting jack.
8 Place a rod through the upper yoke pivot pin
and twist to remove the pin. Use a soft metal
drift to drive the lower yoke pivot pin down and
out.
Crushing hazard. The yoke/hub
assembly may become
unbalanced and fall when the yoke
pivot pins are removed if not
properly supported and secured to
the lifting jack.
Torque specifications
Lug nut torque, dry 125 ft-lbs
169.5 Nm
Lug nut torque, lubricated 94 ft-lbs
127.4 Nm
Steer Axle Components
Yoke and Hub
How to Remove the Yoke
and Hub
The yoke installation utilizes bushings in the axle
and a thrust washer that may require periodic
replacement.
1 Remove the cotter pin from the steer cylinder
rod-end clevis pin and remove the cotter pin
from the tie rod clevis pin. Remove the clevis
pins.
Note: Always use a new cotter pin when installing a
clevis pin.
a tie rod
b steer axle
c yoke pivot pin
d yoke
e hub
f pivot pin
g steer cylinder
Service Manual Supplement
REV B
ab
e
d
f
g
c
f

Part No. 107713 Self-Propelled Servicing Platform
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How to Remove the
Hub and Bearings
1 Loosen the wheel lug nuts. Do not remove
them.
2 Block the non-steer wheels and place a lifting
jack of ample capacity under the steering axle.
3 Raise the machine 6 inches / 15 cm and place
blocks under the chassis for support.
4 Remove the lug nuts. Remove the tire and
wheel assembly.
5 Remove the dust cap, cotter pin and castle nut.
6 Pull the hub off the spindle. The washer and
outer bearing should fall loose from the hub.
7 Place the hub on a flat surface and gently pry
the bearing seal out of the hub. Remove the
rear bearing.
How to Install the
Hub and Bearings
Note: When replacing a wheel bearing, both the
inner and outer bearings including the pressed-in
races must be replaced.
1 Be sure that both bearings are packed
with clean, fresh grease.
2 Place the large inner bearing into the rear
of the hub.
3 Press the bearing seal evenly into the hub
until it is flush.
4 Slide the hub onto the yoke spindle.
Component damage. Do not
apply excessive force or damage
to the lip of the seal may occur.
5 Place the outer bearing into the hub.
6 Install the washer and castle nut.
7 Tighten the castle nut to 150 ft-lbs / 203 Nm to
seat the bearing.
8 Loosen the slotted nut, then retighten to
35 ft-lbs / 48 Nm.
9 Install a new cotter pin. Bend the cotter pin
to lock it in.
10 Install the dust cap, then the tire and wheel
assembly. Torque the wheel lug nuts to
125 ft-lbs / 169.5 Nm.
STEERING AXLE COMPONENTSREV B