Genie Z-45/25 User manual

Service Manual
Z-45/25
Z-45/25J
IC Power
Part No. 77809
Rev C2
August 2005
Serial Number Range
Deutz models: from 21180 to 23040
Ford models: from 21180 to 23189
Perkins models: from 21180 to 23008

Z-45/25 • Z-45/25J Part No. 77809
March 2005
ii
Introduction
Important
Read, understand and obey the safety rules and
operating instructions in the Genie Z-45/25 and
Genie Z-45/25J Operator's Manual before
attempting any maintenance or repair procedure.
This manual provides detailed scheduled
maintenance information for the machine owner
and user. It also provides troubleshooting fault
codes and repair procedures for qualified service
professionals.
Basic mechanical, hydraulic and electrical skills
are required to perform most procedures.
However, several procedures require specialized
skills, tools, lifting equipment and a suitable
workshop. In these instances, we strongly
recommend that maintenance and repair be
performed at an authorized Genie dealer service
center.
Technical Publications
Genie Industries has endeavored to deliver the
highest degree of accuracy possible. However,
continuous improvement of our products is a Genie
policy. Therefore, product specifications are
subject to change without notice.
Readers are encouraged to notify Genie of errors
and send in suggestions for improvement. All
communications will be carefully considered for
future printings of this and all other manuals.
Contact Us:
http://www.genieindustries.com
e-mail: [email protected]
Serial Number Information
Genie Industries offers the following Service
Manuals for these models:
Title PartNo.
Z-45/25 and Z-45/25J Service Manual ................. 52709
From serial number 9998 to 21179
Z-45/25 and Z-45/25J Service Manual ................. 77809
Deutz models: from 21180 to 23040
Ford models: from 21180 to 23189
Perkins models: from 21180 to 23008
Z-45/25 and Z-45/25J Service Manual ............... 107846
Deutz models: from 23041 to 34010
Ford models: from 23190 to 34010
Perkins models: from 23009 to 34010
All models: from A34011 to A47000
All models: from B101
Z-45/25 and Z-45/25J Service Manual ............... 219418
From serial number 13A-47001
Copyright © 2003 by Genie Industries
77809 Rev C March 2005
"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.

Part No. 77809 Genie Z-45/25 and Genie Z-45/25J
March 2005
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 and
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 and Genie Z-45/25J Part No. 77809
March 2005
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.
Used to indicate the presence of
an imminently hazardous situation
which, if not avoided, will result in
death or serious injury.
Used to indicate the presence of a
potentially hazardous situation
which, if not avoided, could result
in death or serious injury.
With safety alert symbol—used to
indicate the presence of a
potentially hazardous situation
which, if not avoided, may result in
minor or moderate injury.
Without safety alert symbol—used
to indicate the presence of a
potentially hazardous situation
which, if not avoided, may result in
property damage.
Used to indicate operation or
maintenance information.
Be sure 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 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.
Be sure that your workshop or work area
is properly ventilated and well lit.

Part No. 77809 Z-45/25 • Z-45/25J
August 2005
Table of Contents
v
Introduction
Important Information .................................................................................................. ii
Section 1 Safety Rules
General Safety Rules ................................................................................................. iii
Section 2 Rev Specifications
A Machine Specifications .......................................................................................... 2 - 1
B Performance Specifications ................................................................................... 2 - 1
B Hydraulic Specifications ........................................................................................ 2 - 2
B Manifold Component Specifications ...................................................................... 2 - 4
A Ford LRG-425 EFI Engine Specifications .............................................................. 2 - 5
A Deutz F3L-1011F Engine Specifications................................................................ 2 - 7
A Perkins 104-22 Engine Specifications ................................................................... 2 - 8
A Machine Torque Specifications............................................................................ 2 - 10
B Hydraulic Hose and Fitting Torque Specifications ............................................... 2 - 11
A SAE and Metric Fastener Torque Chart .............................................................. 2 - 12
Section 3 Rev Scheduled Maintenance Procedures
Introduction ........................................................................................................... 3 - 1
Pre-Delivery Preparation ....................................................................................... 3 - 3
Maintenance Inspection Report ............................................................................. 3 - 5
EChecklist A Procedures
A-1 Perform Pre-operation Inspection ................................................................ 3 - 7
A-2 Perform Function Tests ............................................................................... 3 - 7
A-3 Perform Engine Maintenance - Deutz Models .............................................. 3 - 8
A-4 Perform Engine Maintenance - Ford Models ................................................ 3 - 8
A-5 Perform Engine Maintenance - Perkins Models ........................................... 3 - 9

Z-45/25 • Z-45/25J Part No. 77809
June 2005
TABLE OF CONTENTS
vi
Section 3 Rev Scheduled Maintenance Procedures, continued
A-6 Check the High Pressure Hydraulic Filter Condition Indicator ...................... 3 - 9
A-7 Test the Oscillate Axle (if equipped) .......................................................... 3 - 10
A-8 Perform 30 Day Service ............................................................................. 3 - 10
A-9 Perform Engine Maintenance - Ford and Perkins Models .......................... 3 - 11
A-10 Replace the Fuel Filters - Ford Models ...................................................... 3 - 11
A-11 Inspect the Fuel Filter/Water Separator - Diesel Models ............................ 3 - 13
A-12 Check and Adjust the Engine RPM - Perkins Models ................................ 3 - 15
A-13 Grease the Turntable Rotation Bearing and Rotate Gear .......................... 3 - 16
A-14 Perform Engine Maintenance - Ford Models.............................................. 3 - 16
A-15 Perform Engine Maintenance - Perkins Models ......................................... 3 - 17
DChecklist B Procedures
B-1 Inspect the Battery ..................................................................................... 3 - 18
B-2 Inspect the Electrical Wiring ....................................................................... 3 - 18
B-3 Test the Key Switch ................................................................................... 3 - 19
B-4 Perform Engine Maintenance - Ford Models .............................................. 3 - 20
B-5 Check the Exhaust System ........................................................................ 3 - 20
B-6 Check the Oil Cooler and Cooling Fins - Deutz Models ............................. 3 - 21
B-7 Check the Lug Nut Torque (including the tires and wheels) ....................... 3 - 22
B-8 Confirm the Proper Brake Configuration .................................................... 3 - 22
B-9 Check the Oil Level in the Drive Hubs ....................................................... 3 - 23
B-10 Check and Adjust the Engine RPM - Ford and Deutz Models .................... 3 - 23
B-11 Test the Ground Control Override .............................................................. 3 - 24

Part No. 77809 Z-45/25 • Z-45/25J
June 2005
TABLE OF CONTENTS
vii
Section 3 Rev Scheduled Maintenance Procedures,continued
B-12 Check the Directional Valve Linkage ......................................................... 3 - 25
B-13 Test the Platform Self-leveling ................................................................... 3 - 25
B-14 Test the Engine Idle Select ........................................................................ 3 - 26
B-15 Test the Fuel Select Operation - Ford Models ........................................... 3 - 26
B-16 Test the Drive Brakes ................................................................................ 3 - 27
B-17 Test the Drive Speed - Stowed Position .................................................... 3 - 28
B-18 Test the Drive Speed - Raised or Extended Position ................................. 3 - 28
B-19 Test the Alarm Package (if equipped) ........................................................ 3 - 29
B-20 Perform Hydraulic Oil Analysis .................................................................. 3 - 30
B-21 Replace the Fuel Filter/Water Separator Element - Perkins Models .......... 3 - 31
B-22 Replace the Fuel Filter Element - Perkins Models ..................................... 3 - 33
B-23 Perform Engine Maintenance - Deutz Models ............................................ 3 - 34
B-24 Perform Engine Maintenance - Ford Models.............................................. 3 - 35
B-25 Perform Engine Maintenance - Perkins Models ......................................... 3 - 35
CChecklist C Procedures
C-1 Perform Engine Maintenance - Deutz Models ............................................ 3 - 36
C-2 Grease the Platform Overload Mechanism (if equipped) ........................... 3 - 36
C-3 Test the Platform Overload Mechanism (if equipped) ................................ 3 - 37
C-4 Perform Engine Maintenance - Perkins Models ......................................... 3 - 39
C-5 Perform Engine Maintenance - Ford Models.............................................. 3 - 39

Z-45/25 • Z-45/25J Part No. 77809
June 2005
Section 3 Rev Scheduled Maintenance Procedures,continued
DChecklist D Procedures
D-1 Check the Boom Wear Pads ..................................................................... 3 - 40
D-2 Check the Turntable Rotation Bearing Bolts .............................................. 3 - 40
D-3 Check the Free-wheel Configuration .......................................................... 3 - 42
D-4 Replace the Drive Hub Oil ......................................................................... 3 - 43
D-5 Check and Adjust the Air/LPG Mixture - Ford Models ................................ 3 - 44
D-6 Perform Engine Maintenance - Deutz Models ............................................ 3 - 45
D-7 Inspect for Turntable Bearing Wear ........................................................... 3 - 45
D-8 Calibrate the Platform Overload System (if equipped) ............................... 3 - 47
D-9 Replace the Hydraulic Filters ..................................................................... 3 - 48
BChecklist E Procedures
E-1 Test or Replace the Hydraulic Oil .............................................................. 3 - 50
E-2 Change the Fuel Hoses - Ford Models ...................................................... 3 - 52
E-3 Perform Engine Maintenance - Deutz Models ............................................ 3 - 53
E-4 Grease the Steer Axle Wheel Bearings, 2WD Models ............................... 3 - 53
Section 4 Rev Repair Procedures
Introduction ........................................................................................................... 4 - 1
CPlatform Controls
1-1 ALC-500 Circuit Board ................................................................................. 4 - 2
1-2 Joysticks ...................................................................................................... 4 - 3
APlatform Components
2-1 Platform Leveling Slave Cylinder ................................................................. 4 - 7
2-2 Platform Rotator........................................................................................... 4 - 8
viii
TABLE OF CONTENTS

Part No. 77809 Genie Z-45/25 and Genie Z-45/25J
March 2005
Section 4 Rev Repair Procedures, continued
BJib Boom Components, Z-45/25J
3-1 Jib Boom .................................................................................................... 4 - 10
3-2 Jib Boom Lift Cylinder ................................................................................ 4 - 11
APrimary Boom Components
4-1 Cable Track ............................................................................................... 4 - 12
4-2 Primary Boom ............................................................................................ 4 - 16
4-3 Primary Boom Lift Cylinder ........................................................................ 4 - 18
4-4 Primary Boom Extension Cylinder ............................................................. 4 - 19
4-5 Platform Leveling Master Cylinder ............................................................. 4 - 20
ASecondary Boom Components
5-1 Secondary Boom ....................................................................................... 4 - 22
5-2 Secondary Boom Lift Cylinders .................................................................. 4 - 27
BEngines
6-1 RPM Adjustment - Ford and Deutz Models ................................................ 4 - 28
6-2 RPM Adjustment - Perkins Models ............................................................ 4 - 28
6-3 Flex Plate ................................................................................................... 4 - 28
6-4 Engine Fault Codes - Ford Models ............................................................ 4 - 29
AHydraulic Pumps
7-1 Lift/Steer Pump .......................................................................................... 4 - 31
7-2 Drive Pump ................................................................................................ 4 - 32
ix
TABLE OF CONTENTS

Genie Z-45/25 and Genie Z-45/25J Part No. 77809
March 2005
TABLE OF CONTENTS
Section 4 Rev Repair Procedures, continued
BManifolds
8-1 Function Manifold Components (before serial number 22050) ................... 4 - 34
8-2 Valve Adjustments - Function Manifold (before serial number 22050) ....... 4 - 38
8-3 Function Manifold Components (after serial number 22049) ...................... 4 - 40
8-4 Valve Adjustments - Function Manifold (after serial number 22049) .......... 4 - 44
8-5 Jib Boom / Platform Rotate Manifold Components
(before serial number 22050) ..................................................................... 4 - 45
8-6 Jib Boom / Platform Rotate Manifold Components
(after serial number 22049) ........................................................................ 4 - 46
8-7 Turntable Rotation Manifold Components .................................................. 4 - 47
8-8 Directional Valve Manifold Components .................................................... 4 - 48
8-9 Drive Manifold Components, 2WD ............................................................. 4 - 50
8-10 Valve Adjustments, 2WD Drive Manifold ................................................... 4 - 52
8-11 Drive Manifold Components, 4WD ............................................................. 4 - 54
8-12 Valve Adjustments, 4WD Drive Manifold ................................................... 4 - 56
.ATurntable Rotation Components
9-1 Turntable Rotation Assembly ..................................................................... 4 - 57
BAxle Components
10-1 Hub and Bearings, 2WD Models ................................................................ 4 - 58
10-2 Oscillate Lock-out Cylinders ...................................................................... 4 - 59
Section 5 Rev Fault Codes
Introduction ........................................................................................................... 5 - 1
B Fault Codes - Control System ............................................................................... 5 - 2
B Fault Codes - Ford Models .................................................................................... 5 - 6
x

Part No. 77809 Genie Z-45/25 and Genie Z-45/25J
March 2005
TABLE OF CONTENTS
Section 6 Rev Schematics
Introduction ........................................................................................................... 6 - 1
B Electrical Symbols Legend .................................................................................... 6 - 2
B Hydraulic Symbols Legend .................................................................................... 6 - 3
Ford LRG-425 EFI models
A Engine Harness (before serial number 22050) ...................................................... 6 - 5
A Engine Harness (after serial number 22049) ......................................................... 6 - 6
A Electrical Schematic, Z-45/25 (before serial number 22050) ................................. 6 - 7
A Electrical Schematic, Z-45/25 (after serial number 22049) .................................... 6 - 9
A Ground Control Box Terminal Strip Wiring Diagram, Z-45/25
(before serial number 22050) .............................................................................. 6 - 11
A Ground Control Box Switch Panel Wiring Diagram, Z-45/25
(before serial number 22050) .............................................................................. 6 - 12
A Ground Control Box Terminal Strip Wiring Diagram, Z-45/25
(after serial number 22049) ................................................................................. 6 - 13
A Ground Control Box Switch Panel Wiring Diagram, Z-45/25
(after serial number 22049) ................................................................................. 6 - 14
A Platform Control Box Terminal Strip Wiring Diagram, Z-45/25
(before serial number 22050) .............................................................................. 6 - 15
A Platform Control Box Switch Panel Wiring Diagram, Z-45/25
(before serial number 22050) .............................................................................. 6 - 16
A Platform Control Box Terminal Strip Wiring Diagram, Z-45/25
(after serial number 22049) ................................................................................. 6 - 17
A Platform Control Box Switch Panel Wiring Diagram, Z-45/25
(after serial number 22049) ................................................................................. 6 - 18
xi

Genie Z-45/25 and Genie Z-45/25J Part No. 77809
March 2005
TABLE OF CONTENTS
xii
Section 6 Rev Schematics, continued
Ford LRG-425 EFI models, continued
A Electrical Schematic, Z-45/25J (before serial number 22050) ............................. 6 - 19
A Electrical Schematic, Z-45/25J (after serial number 22049) ................................ 6 - 21
A Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J
(before serial number 22050) .............................................................................. 6 - 23
A Ground Control Box Switch Panel Wiring Diagram, Z-45/25J
(before serial number 22050) .............................................................................. 6 - 24
A Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J
(after serial number 22049) ................................................................................. 6 - 25
A Ground Control Box Switch Panel Wiring Diagram, Z-45/25J
(after serial number 22049) ................................................................................. 6 - 26
A Platform Control Box Terminal Strip Wiring Diagram, Z-45/25J
(before serial number 22050) .............................................................................. 6 - 27
A Platform Control Box Switch Panel Wiring Diagram, Z-45/25J
(before serial number 22050) .............................................................................. 6 - 28
A Platform Control Box Terminal Strip Wiring Diagram, Z-45/25J
(after serial number 22049) ................................................................................. 6 - 29
A Platform Control Box Switch Panel Wiring Diagram, Z-45/25J
(after serial number 22049) ................................................................................. 6 - 30

Part No. 77809 Genie Z-45/25 and Genie Z-45/25J
March 2005
Section 6 Rev Schematics, continued
Deutz F3L-1011F models
A Electrical Schematic, Z-45/25 (before serial number 22050) ............................... 6 - 31
A Electrical Schematic, Z-45/25 (after serial number 22049) .................................. 6 - 33
A Electrical Schematic, Z-45/25 (after serial number 22049)
CE models ........................................................................................................... 6 - 35
A Ground Control Box Terminal Strip Wiring Diagram, Z-45/25
(before serial number 22050) .............................................................................. 6 - 37
A Ground Control Box Switch Panel Wiring Diagram, Z-45/25
(before serial number 22050) .............................................................................. 6 - 38
A Ground Control Box Terminal Strip Wiring Diagram, Z-45/25
(after serial number 22049) ................................................................................. 6 - 39
A Ground Control Box Switch Panel Wiring Diagram, Z-45/25
(after serial number 22049) ................................................................................. 6 - 40
A Ground Control Box Terminal Strip Wiring Diagram, Z-45/25
CE Models (after serial number 22049) ............................................................... 6 - 41
A Ground Control Box Switch Panel Wiring Diagram, Z-45/25
CE Models (after serial number 22049) ............................................................... 6 - 42
A Platform Control Box Terminal Strip Wiring Diagram, Z-45/25
(before serial number 22050) .............................................................................. 6 - 43
A Platform Control Box Switch Panel Wiring Diagram, Z-45/25
(before serial number 22050) .............................................................................. 6 - 44
A Platform Control Box Terminal Strip Wiring Diagram, Z-45/25
(after serial number 22049) ................................................................................. 6 - 45
A Platform Control Box Switch Panel Wiring Diagram, Z-45/25
(after serial number 22049) ................................................................................. 6 - 46
A Electrical Schematic, Z-45/25J (before serial number 22050) ............................. 6 - 47
A Electrical Schematic, Z-45/25J (after serial number 22049) ................................ 6 - 49
A Electrical Schematic, Z-45/25J (after serial number 22049)
CE models ........................................................................................................... 6 - 51
TABLE OF CONTENTS
xiii

Genie Z-45/25 and Genie Z-45/25J Part No. 77809
March 2005
Section 6 Rev Schematics, continued
Deutz F3L-1011F models, continued
A Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J
(before serial number 22050) .............................................................................. 6 - 53
A Ground Control Box Switch Panel Wiring Diagram, Z-45/25J
(before serial number 22050) .............................................................................. 6 - 54
A Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J
(after serial number 22049) ................................................................................. 6 - 55
A Ground Control Box Switch Panel Wiring Diagram, Z-45/25J
(after serial number 22049) ................................................................................. 6 - 56
A Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J
CE Models (after serial number 22049) ............................................................... 6 - 57
A Ground Control Box Switch Panel Wiring Diagram, Z-45/25J
CE Models (after serial number 22049) ............................................................... 6 - 58
A Platform Control Box Terminal Strip Wiring Diagram, Z-45/25J
(before serial number 22050) .............................................................................. 6 - 59
A Platform Control Box Switch Panel Wiring Diagram, Z-45/25J
(before serial number 22050) .............................................................................. 6 - 60
A Platform Control Box Terminal Strip Wiring Diagram, Z-45/25J
(after serial number 22049) ................................................................................. 6 - 61
A Platform Control Box Switch Panel Wiring Diagram, Z-45/25J
(after serial number 22049) ................................................................................. 6 - 62
TABLE OF CONTENTS
xiv

Part No. 77809 Genie Z-45/25 and Genie Z-45/25J
March 2005
TABLE OF CONTENTS
Section 6 Rev Schematics, continued
Perkins 104-22 models
A Electrical Schematic, Z-45/25 (before serial number 22050) ............................... 6 - 63
A Electrical Schematic, Z-45/25 (after serial number 22049) .................................. 6 - 65
A Ground Control Box Terminal Strip Wiring Diagram, Z-45/25
(before serial number 22050) .............................................................................. 6 - 67
A Ground Control Box Switch Panel Wiring Diagram, Z-45/25
(before serial number 22050) .............................................................................. 6 - 68
A Ground Control Box Terminal Strip Wiring Diagram, Z-45/25
(after serial number 22049) ................................................................................. 6 - 69
A Ground Control Box Switch Panel Wiring Diagram, Z-45/25
(after serial number 22049) ................................................................................. 6 - 70
A Platform Control Box Terminal Strip Wiring Diagram, Z-45/25
(before serial number 22050) .............................................................................. 6 - 71
A Platform Control Box Switch Panel Wiring Diagram, Z-45/25
(before serial number 22050) .............................................................................. 6 - 72
A Platform Control Box Terminal Strip Wiring Diagram, Z-45/25
(after serial number 22049) ................................................................................. 6 - 73
A Platform Control Box Switch Panel Wiring Diagram, Z-45/25
(after serial number 22049) ................................................................................. 6 - 74
A Electrical Schematic, Z-45/25J (before serial number 22050) ............................. 6 - 75
A Electrical Schematic, Z-45/25J (after serial number 22049) ................................ 6 - 77
A Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J
(before serial number 22050) .............................................................................. 6 - 79
A Ground Control Box Switch Panel Wiring Diagram, Z-45/25J
(before serial number 22050) .............................................................................. 6 - 80
A Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J
(after serial number 22049) ................................................................................. 6 - 81
A Ground Control Box Switch Panel Wiring Diagram, Z-45/25J
(after serial number 22049) ................................................................................. 6 - 82
xv

Genie Z-45/25 and Genie Z-45/25J Part No. 77809
March 2005
TABLE OF CONTENTS
Section 6 Rev Schematics, continued
Perkins 104-22 models, continued
A Platform Control Box Terminal Strip Wiring Diagram, Z-45/25J
(before serial number 22050) .............................................................................. 6 - 83
A Platform Control Box Switch Panel Wiring Diagram, Z-45/25J
(before serial number 22050) .............................................................................. 6 - 84
A Platform Control Box Terminal Strip Wiring Diagram, Z-45/25J
(after serial number 22049) ................................................................................. 6 - 85
A Platform Control Box Switch Panel Wiring Diagram, Z-45/25J
(after serial number 22049) ................................................................................. 6 - 86
Hydraulic Schematics
A Hydraulic Schematic, 2WD Models (before serial number 22050) ....................... 6 - 87
B Hydraulic Schematic, 2WD Models (after serial number 22049).......................... 6 - 88
A Hydraulic Schematic, 4WD Models (before serial number 22050) ....................... 6 - 89
B Hydraulic Schematic, 4WD Models (after serial number 22049).......................... 6 - 90
xvi

Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 2 - 1
Section 2 • SpecificationsMarch 2005
REV B Specifications
Machine Specifications
Tires and wheels Rough terrain Industrial
Wheel lugs, 4WD 9 @ 5/8 -18
Wheel lugs, 2WD
Front 9 @ 5/8-18 9 @ 5/8-18
Rear 9 @ 5/8-18 9 @ 5/8-18
Lug nut torque, dry 125 ft-lbs 125 ft-lbs
169.5 Nm 169.5 Nm
Lug nut torque, lubricated 94 ft-lbs 94 ft-lbs
127.4 Nm 127.4 Nm
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 (air filled tires) 45 psi 100 psi
3.1 bar 6.9 bar
Fluid capacities
LPG tank 33.5 pounds
15.2 kg
Hydraulic tank 24 gallons
91 liters
Hydraulic system 30 gallons
(including tank) 113.6 liters
Drive hubs 17 fl oz
0.5 liters
For operational specifications, refer to the
Operator's Manual.
Performance Specifications
Drive speed, maximum
Stowed position 4.8 mph
7.7 km/h
40 ft/5.7 sec
12.2 m/5.7 sec
Raised or extended position 0.3 mph
0.5 km/h
40 ft/45 sec
12.2 m/45 sec
Braking distance, maximum
High range on paved surface 3 to 6 ft
0.9 to 1.8 m
Boom function speeds, maximum
from platform controls
Jib boom up, Z-45/25J 28 to 32 seconds
Jib boom down, Z-45/25J 16 to 20 seconds
Primary boom up 24 to 28 seconds
Primary boom down 24 to 28 seconds
Secondary boom up 24 to 28 seconds
Secondary boom down 38 to 42 seconds
Primary boom extend 14 to 18 seconds
Primary boom retract 16 to 20 seconds
Turntable rotate, 359° 62 to 68 seconds
primary boom retracted
Platform rotate, 180° 5 to 7 seconds
Z-45/25
Platform rotate, 160° 5 to 7 seconds
Z-45/25J
Continuous improvement of our products is a
Genie policy. Product specifications are
subject to change without notice.

2 - 2 Genie Z-45/25 and Genie Z-45/25J Part No. 77809
Section 2 • Specifications March 2005
REV BSPECIFICATIONS
Hydraulic Specifications
Hydraulic Oil Specifications
Hydraulic oil type Chevron Rykon MV equivalent
ISO viscosity grade Multi-viscosity
Viscosity index 200
Cleanliness level, minimum 15/13
Water content, maximum 200 ppm
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
Use Chevron Aviation A hydraulic
oil when in ambient temperatures
consistently below 0°F / -18°C.
Use Shell Tellus T46 hydraulic oil
when oil temperatures consistently
exceed 205°F / 96°C.
Genie specifications require
additional equipment and special
installation instructions for the
approved optional fluids. Consult
the Genie Industries Service
Department before use.
Drive pump
Type: bi-directional, variable
displacement piston pump
Flow rate @ 2500 rpm 30.3 gpm
(before serial number 22050) 114.7 L/min
Flow rate @ 2500 rpm 32 gpm
(after serial number 22049) 121 L/min
Drive pressure, maximum 3500 psi
(before serial number 22050) 241.3 bar
Drive pressure, maximum 3750 psi
(after serial number 22049) 259 bar
Charge pump
Type: gerotor
Displacement 0.85 cu in
(before serial number 22050) 13.9 cc
Displacement 0.84 cu in
(after serial number 22049) 13.76 cc
Flow rate @ 2500 rpm 9.2 gpm
(before serial number 22050) 34.8 L/min
Flow rate @ 2500 rpm 9.1 gpm
(after serial number 22049) 34.4 L/min
Charge pressure @ 2500 rpm 250 psi
(before serial number 22050) 17.2 bar
Charge pressure @ 2500 rpm 315 psi
(after serial number 22049) 21.7 bar
Function pump
Type: gear, pressure balanced
Displacement 0.67 cu in
11 cc
Flow rate @ 2500 rpm 7.25 gpm
27.4 L/min

Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 2 - 3
Section 2 • SpecificationsMarch 2005
REV B
Auxiliary pump
Type: gear, fixed displacement
Displacement 1.75 gpm
2.8 L/min
Auxiliary pump relief pressure 3200 psi
220.6 bar
Function manifold
System relief valve pressure 3200 psi
220.6 bar
Secondary boom down 1800 psi
relief valve pressure 124 bar
Platform level relief valve pressure 3500 psi
(after serial number 22049) 241.3 bar
Steer flow regulator 1.5 gpm
5.7 L/min
Boom extend flow regulator 2 gpm
7.6 L/minSteer
Jib boom / platform rotate flow regulator 0.6 gpm
(before serial number 22050) 2.27 L/min
Jib boom / platform rotate flow regulator 0.4 gpm
(after serial number 22049) 1.5 L/min
Drive manifold
Hot oil relief pressure 250 psi
17.2 bar
Steer end drive motors (4WD models)
Displacement 1.53 cu in
per revolution 25 cc
Non-steer end drive motors
Displacement per revolution, variable 0.16 to 2.8 cu in
4WD (2 speed motor) 2.62 to 45.9 cc
Displacement per revolution, variable 1.1 to 2.8 cu in
2WD 18.4 to 45.9 cc
Hydraulic filters
High pressure filter Beta 3 ³200
High pressure filter 100 psi
bypass pressure 6.89 bar
Medium pressure filter Beta 3 ³200
Medium pressure filter 50 psi
bypass pressure 3.4 bar
Hydraulic return filter 10 micron with
25 psi / 1.7 bar bypass
SPECIFICATIONS

2 - 4 Genie Z-45/25 and Genie Z-45/25J Part No. 77809
Section 2 • Specifications March 2005
REV A
Manifold Component
Specifications
Plug torque
SAE No. 2 50 in-lbs / 6 Nm
SAE No. 4 13 ft-lbs / 18 Nm
SAE No. 6 18 ft-lbs / 24 Nm
SAE No. 8 50 ft-lbs / 68 Nm
SAE No. 10 55 ft-lbs / 75 Nm
SAE No. 12 75 ft-lbs / 102 Nm
Valve coil resistance specifications
(before serial number 22050)
Proportional solenoid valve, 12V DC 4 to 5Ω
(schematic items A, B and KK)
3 position 4 way directional valve, 10V DC 5 to 7Ω
(schematic items R, AA, CC, EE, FF and HH)
2 position 3 way solenoid valve, 10V DC 5 to 7Ω
(schematic items J, K, AI, AK, AU, AV,
OO and XX)
Valve coil resistance specifications
(after serial number 22049)
Proportional directional solenoid valve, 10V DC 6 to 8Ω
(schematic items A, C, D)
3 position 4 way directional valve, 10V DC 6 to 8Ω
(schematic items B, F, H)
2 position 3 way solenoid valve, 10V DC 6 to 8Ω
(schematic items E, G, AD, OO, XX, AI and AK)
SPECIFICATIONS