Genie Z-45/22 Service Manual
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Genie Z-45/22 Service Manual

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Z - 45 2 2
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Service
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First Edition
Part No. 29487

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Summary of Contents for Genie Z-45/22

  • Page 1 Technical Publications Z - 45 2 2 ® Service Manual First Edition Part No. 29487...
  • Page 2 Operating Instruction Manual before attempting Toll Free 800 536-1800 any maintenance or repair procedure. Fax (206) 883-3475 This service manual covers the Genie Z-45/22 Telex 152351 2WD and 4WD models introduced in 1991. Genie Europe This manual provides detailed scheduled...
  • Page 3 Section 1 - Safety Rules Safety Rules Danger Failure to obey the instructions and safety rules in this manual, and the Genie Z-45/22 Operating Instruction Manual will result in death or serious injury. Many of the hazards identified in the operating...
  • Page 4 Be sure to properly dispose of old oil or unsecured components, and lifting or other fluids. Use an approved container. placing loads. Always wear approved steel-toed Please be mindful of the environment. shoes. Genie Z-45/22 Part No. 29487...

  • Page 5: Table Of Contents

    Check the Engine Coolant Level ..............4 - 3 Check for Fuel Leaks ..................4 - 3 Check the Hydraulic Oil Level ................. 4 - 4 Check for Hydraulic Leaks ................4 - 4 Check Tire Pressure ..................4 - 4 Part No. 29487 Genie Z-45/22...
  • Page 6 B-20 Test the Foot Switch ..................4 - 19 B-21 Test the Engine Speed Select ..............4 - 20 B-22 Test Fuel Select Operation - Gasoline/LPG Models ........4 - 20 B-23 Test the Turntable Rotation Stop ..............4 - 21 Genie Z-45/22 Part No. 29487...
  • Page 7 Clean PCV Hoses, Tubes, and Fittings - Gasoline/LPG Models ....4 - 37 Check the Engine Nozzle Injection Pressure - Diesel Models ...... 4 - 38 Check Injection Timing - Diesel Models ............4 - 38 Replace The Timing Belt - Ford ..............4 - 38 Part No. 29487 Genie Z-45/22...
  • Page 8 Turntable Rotate Right Function Inoperative ..........5 - 39 All Platform Leveling Functions Inoperative ..........5 - 40 Platform Level Up Function Inoperative ............5 - 41 Platform Level Down Function Inoperative ........... 5 - 42 Genie Z-45/22 Part No. 29487 viii...
  • Page 9 Ground Control Box Legend - Diesel Models ............6-10 Relay Panel Legend - Diesel Models ................ 6-11 Platform Control Box Legend - Diesel Models ............6-12 Hydraulic Symbols Legend ..................6-13 2WD Hydraulic Schematic ..................6-14 4WD Hydraulic Schematic ..................6-15 Part No. 29487 Genie Z-45/22...
  • Page 10 Glow Plugs ....................7 - 28 RPM Adjustment ................... 7 - 28 Flex Plate ...................... 7 - 28 Water Temperature and Oil Pressure Switches ..........7 - 28 Ford LSG 423 Engine Governor Actuator ..................7 - 30 Genie Z-45/22 Part No. 29487...
  • Page 11 13-1 Rotation Hydraulic Motor ................7 - 48 13-2 Rotation Bearing and Worm Drive ..............7 - 48 2WD Steering Axle Components 14-1 Yoke and Hub ....................7 - 53 14-2 Steering Cylinders ..................7 - 54 Part No. 29487 Genie Z-45/22...
  • Page 12 19-1 2WD Drive Manifold Components ..............7 - 62 19-2 Valve Adjustments ..................7 - 64 4WD Drive Manifold 20-1 4WD Drive Manifold Components ..............7 - 66 20-2 Valve Adjustments ..................7 - 68 Genie Z-45/22 Part No. 29487...

  • Page 13: Specifications

    190.5cm 190.5cm 0.5 liters Continuous improvement of our products is a Minimum turning radius, 14 ft 4 in 14 ft 9 in Genie policy. Product specifications are subject to outside 4.37m 4.49m change without notice. Minimum turning radiius, 7 ft...

  • Page 14: Performance Specifications

    73 seconds Platform rotate (180°) 15 seconds Platform level up 25 seconds Platform level down 15 seconds Multiple function 60 seconds stowed to full raised Multiple function 60 seconds full lowered to stowed 2 - 2 Genie Z-45/22 Part No. 29487...
  • Page 15 Function relief 2200psi 138 bar valve pressure 1200 psi Secondary down relief 83 bar valve pressure 1200 psi Primary down relief 83 bar valve pressure 1.5 gpm Steer/oscillate 5.7 liters/minute flow regulator Part No. 29487 Genie Z-45/22 2 - 3...
  • Page 16 Torque - Dry Torque - Dry inch-pounds foot-pounds Newton meters inch-pounds foot-pounds Newton meters 1221 1000 1356 Torque specification for lubricated bolts is 25% less than dry torque specification for bolt size. 2 - 4 Genie Z-45/22 Part No. 29487...

  • Page 17: Ford Lsg 423 Engine Specifications

    10W - 40 or 10W - 50 above 25°F / -4°C 20W - 40 or 20W - 50 Use oils meeting API classification SF (labeled SF/CC or SF/CD) as they offer improved wear protection. Part No. 29487 Genie Z-45/22 2 - 5...
  • Page 18 6 - 9 8 - 12 Inner timing belt cover stud / M-8 14 - 21 19 - 28 Outer timing belt cover bolt / M-6 6 - 9 8 - 12 2 - 6 Genie Z-45/22 Part No. 29487...

  • Page 19: Kubota V1702-B Engine Specifications

    Coolant capacity 17 - 24 24 - 27 7.25 quarts / 6.9 liters Rocker arm mounting nuts Alternator output 8 - 18 11 - 24 35A, 14V Temperature sending unit to block Part No. 29487 Genie Z-45/22 2 - 7...
  • Page 20 76 - 86 103 - 117 M-14 123 - 144 168 - 196 M-16 192 - 224 260 - 304 M-18 253 - 296 343 - 402 M-20 362 - 419 490 - 568 2 - 8 Genie Z-45/22 Part No. 29487...

  • Page 21: Scheduled Maintenance Inspections

    Keep records on all inspections for three years. · Two year inspection Use checklists A, B, C and D Make copies of this form to use for each inspection. Store completed forms for three years. Part No. 29487 Genie Z-45/22 3 - 1...
  • Page 22 Every 100 hours, check for and/or perform as necessary the engine maintenance procedures listed below. A-14 Replace the Engine Oil and Filter A-15 Change the Engine Air Filter A-16 Drain the Fuel Filter/Water Separator - Diesel Models 3 - 2 Genie Z-45/22 Part No. 29487...
  • Page 23 B-13 Check and Adjust the Engine RPM B-14 Test the Key Switch B-15 Test the Emergency Stop Buttons B-16 Test the Ground Control Override B-17 Test the Oscillate Lock-out oscillating axle equipped models Part No. 29487 Genie Z-45/22 3 - 3...
  • Page 24 C-2 Check the Turntable Rotation Bearing Bolts C-3 Check the Free-wheel Feature Grease the Worm Drive Gear including turntable rotation bearing C-5 Replace the Torque Hub Oil C-6 Replace the Hydraulic Reservoir Filter 3 - 4 Genie Z-45/22 Part No. 29487...
  • Page 25 D-6 Clean PCV Hoses and Fittings - Gasoline/LPG Models D-7 Check the Engine Nozzle Injection Pressure - Diesel Models D-8 Check Injection Timing - Diesel Models D-9 Replace the Timing Belt - Ford Part No. 29487 Genie Z-45/22 3 - 5...

  • Page 26: Maintenance Inspection Report

    B-12 Idle mixture-gasoline fittings-gasoline B-13 Engine RPM D-7 Engine injection nozzle B-14 Key switch -diesel B-15 Emergency Stop button D-8 Injection timing-diesel B-16 Ground control override D-9 Timing belt-Ford B-17 Oscillate lock-out 3 - 6 Genie Z-45/22 Part No. 29487...

  • Page 27: Scheduled Maintenance Procedures

    Indicates that a specific result is expected after performing a series of steps. Repair any machine damage or malfunction before operating machine. Keep records on all inspections for three years. Part No. 29487 Genie Z-45/22 4 - 1...

  • Page 28: Inspect The Operating Instruction And Safety Manuals

    Table A Procedures 2 Inspect all decals for damage or illegibility. Replace any illegible decal immediately. Inspect the Operating Instruction Contact your Genie distributor or and Safety Manuals Genie Industries if replacement decals are needed. Maintaining the Operating Instruction and Safety manuals in good condition is essential to safe machine operation.

  • Page 29: Check The Engine Oil Level

    Daily checks will allow the entering the area and do not inspector to identify dramatic changes in coolant operate the machine. Repair the level that might indicate cooling system problems. leak immediately. Part No. 29487 Genie Z-45/22 4 - 3...

  • Page 30: Check The Hydraulic Oil Level

    14-17.5NHS 28 psi / 1.93 bar residue on or around the following areas: · hydraulic reservoir—fittings, hoses and turntable surface · engine compartment—fittings, hoses, auxiliary power unit, main pump and turntable surface 4 - 4 Genie Z-45/22 Part No. 29487...

  • Page 31: Test The Platform And Ground Controls

    3 Turn the key switch to platform control. including the Emergency Stop 4 At the platform controls, pull out the button. Emergency Stop button to the on position, press down the foot switch and repeat step 2. Part No. 29487 Genie Z-45/22 4 - 5...

  • Page 32: Test The Tilt Level Sensor

    1 With the engine off and the machine in the stowed position, visually inspect the drive limit Elevated position switch for the following: 1 foot / 0.3 meter per second 2WD and 4WD 4 - 6 Genie Z-45/22 Part No. 29487...
  • Page 33 4 Swing the turntable to the right until the platform is positioned over the right steer wheel. Result: The platform over steer wheels indicator light should be on. Drive movement should stop until the drive enable override switch is activated. Part No. 29487 Genie Z-45/22 4 - 7...

  • Page 34: Replace The Engine Oil And Filter

    2 Pull the end of the oil drain hose out from under 11 Check the engine oil level dipstick. Add oil if the engine. needed. pivot plate bolts oil drain hose 4 - 8 Genie Z-45/22 Part No. 29487...

  • Page 35: Change The Engine Air Filter

    2 Remove the mounting fastener from the air filter, and then remove the air filter. 3 Insert the new air filter and replace the mounting fasteners. 4 Replace the end cap on the canister. Part No. 29487 Genie Z-45/22 4 - 9...

  • Page 36: Drain The Fuel Filter/Water Separator - Diesel Models

    Always have an approved fire extinguisher within easy reach. Fuel filter/water seperator head bolt filter bowl drain plug vent plug separator head 4 - 10 Genie Z-45/22 Part No. 29487...

  • Page 37: Check The Engine Fan Belts

    Also, restricting air flow through the radiator (i.e., dirt or debris) will affect the performance of the cooling system. A frequent Part No. 29487 Genie Z-45/22 4 - 11...

  • Page 38: Check The Battery

    Result: The filter should be operating in the green area. If the display shows red, this indicates that the hydraulic filter is being bypassed and the filter should be replaced. 4 - 12 Genie Z-45/22 Part No. 29487...

  • Page 39: Inspect Electrical Wiring

    Tire pressure - 4WD · primary boom to platform cable harness Sidewall 6 · inside of the platform control box 40 psi 100 psi 2.76 bar6.89 bar 28 psi 1.93 bar Part No. 29487 Genie Z-45/22 4 - 13...

  • Page 40: Confirm Proper Brake Configuration

    4 Repeat this procedure for each torque hub. free-wheel valve Specifications Capacity 17 fluid ounces / 0.5 liters Type SAE 90 multipurpose hypoid gear oil - API service classification GL5 4 - 14 Genie Z-45/22 Part No. 29487...

  • Page 41: Check The Engine Choke - Gasoline/Lpg Models

    Result: The volt meter should read 12 volts. 3 While operating the choke switch, inspect the choke solenoid. Result: The choke solenoid should be fully retracted when the choke switch is activated. Part No. 29487 Genie Z-45/22 4 - 15...

  • Page 42: Check And Adjust The Engine Idle Mixture - Gasoline/Lpg Models

    Mixture - Gasoline/LPG Models Complete information to perform this procedure is available in the Ford LSG-423 2.3 Litre Industrial Engine Service Manual (Ford number: 194-216). Genie part number 29586. Ford low idle adjustment adjustment screw B-13 3 Move the engine speed control switch to high Check and Adjust idle (rabbit symbol) from the ground controls.

  • Page 43: Test The Key Switch

    11 Reconnect the rubber boot to the solenoid. functions should operate. Then tighten the lock nut and recheck the rpm. Specifications Ford and Kubota Engines 1200 rpm Low idle 2150 rpm High idle Part No. 29487 Genie Z-45/22 4 - 17...

  • Page 44: Test The Emergency Stop Buttons

    The ground chassis frame. The boom should stop moving control override function is intended to allow until the wedges are fully extended. ground personnel to operate the machine from the 4 - 18 Genie Z-45/22 Part No. 29487...

  • Page 45: Test Platform Self-Leveling

    3 Press down the foot switch and operate the full cycle. machine functions. Result: The platform should remain level at all Result: The machine functions should operate. times to within ±5 degrees. Part No. 29487 Genie Z-45/22 4 - 19...

  • Page 46: Test The Engine Speed Select

    (rabbit and foot 4 Release the foot switch and stop the engine. switch symbol). 5 Move the fuel select switch to propane gas. 4 - 20 Genie Z-45/22 Part No. 29487...

  • Page 47: Test The Turntable Rotation Stop

    Test the Drive Enable System 6 Repeat steps 3 and 4. Proper drive enable system operation is essential to safe machine operation. When the platform is over the steering wheels, drive movement is Part No. 29487 Genie Z-45/22 4 - 21...

  • Page 48: Test The Drive Brakes

    Distance: 20 feet / 6 meters 2.85 seconds (±0.25 Specifications: high range, paved surface seconds) Stopping distance, 5.5 to 6 feet / 2.75 seconds (±0.25 normal operating temp. 1.67 to 1.82 meters seconds) 4 - 22 Genie Z-45/22 Part No. 29487...

  • Page 49: Test The Alarm Package (Optional Equipment)

    Now move the secondary boom switch to the down position, hold for a moment and then release it. Result: The descent alarm should sound when each switch is held down. Part No. 29487 Genie Z-45/22 4 - 23...

  • Page 50: Check The Primary Boom Wear Pads

    (78cm) block between the chassis bearing. counterweight and the upper mid-pivot. 6 Loosen the counterwight positioning bolt, then Carefully lower the secondary boom onto the remove the 2 mounting bolts. block. 4 - 24 Genie Z-45/22 Part No. 29487...

  • Page 51: Check The Free-Wheel Feature

    (5000 lbs / 2268kg) under the chassis between the rear drive wheels. 3 Lift the wheels off the ground and then place jack stands under the chassis for support. drive pump lift pump free-wheel valve Part No. 29487 Genie Z-45/22 4 - 25...
  • Page 52 Specification Multipurpose grease upper mid-pivot 4x4x31 inch block counterweight Crushing hazard. Keep hands away from the block and all moving parts when lowering the secondary boom. 4 - 26 Genie Z-45/22 Part No. 29487...

  • Page 53: Replace The Torque Hub Oil

    Then re-install the plugs. 5 Repeat steps 1 through 4 for all the other drive torque hubs. Specifications Capacity 17 fluid ounces 0.5 liters SAE 90 multipurpose Type hypoid gear oil. API classification GL5 Part No. 29487 Genie Z-45/22 4 - 27...

  • Page 54: Replace The Drive Loop Hydraulic Filter

    2 Place a container under the bowl and then loosen the drain plug located at the bottom of the bowl. Completely drain the bowl. 3 Loosen the head bolt then rotate the bowl counterclockwise and remove it. 4 - 28 Genie Z-45/22 Part No. 29487...

  • Page 55: Replace The Gasoline Fuel Filter

    Replace the fuel filter in an open, leak immediately. well-ventilated area away from heaters, sparks, flames and lighted tobacco. Always have an approved fire extinguisher within easy reach. Perform this procedure with the engine off. Part No. 29487 Genie Z-45/22 4 - 29...

  • Page 56: Replace The Pcv Valve - Gasoline/Lpg Models

    Moisture in the distributor cap will cause the engine to run poorly. 6 Inspect the cap and rotor for corrosion, cracks and abrasion. Replace the cap and rotor if they are damaged. 4 - 30 Genie Z-45/22 Part No. 29487...

  • Page 57: Replace The Spark Plugs - Gasoline/Lpg Models

    Spark Plugs (Motorcraft) 0.032 - 0.036 inches 0.81 - 0.91mm 5 - 10 foot-pounds Torque specs 6.8 - 13.6 Nm low idle mixture adjustment screw high idle mixture adjustment screw propane regulator pressure adjustment Part No. 29487 Genie Z-45/22 4 - 31...

  • Page 58: Check And Adjust The Ignition Timing - Gasoline/Lpg Models

    13.0:1 to 13.2:1, available in the Ford LSG-423 2.3 Litre Industrial using an exhaust gas analyzer. Engine Service Manual (Ford number: 194-216). Genie part number 29586. If an exhaust gas analyzer is not available, adjust to obtain peak or optimum rpm.

  • Page 59: Change The Hydraulic Oil

    (including tank) 114 liters reservoir. Hydraulic fluid Dexron II equivalent 5 Remove the strainer assemblies from the reservoir. 6 Carefully clean any foreign material from the strainers. Part No. 29487 Genie Z-45/22 4 - 33...

  • Page 60: Change Or Recondition The Engine Coolant

    Reconnect the coolant return hose to the radiator. 6 Open the petcock on the engine block and allow the coolant to drain into a container. After the fluid is drained, close the petcock. 4 - 34 Genie Z-45/22 Part No. 29487...

  • Page 61: Change The Fuel Lines

    Refer to the Kubota V1702-B Diesel Engine Workshop Manual (Kubota code number: 97897-00691) for information on how to bleed the fuel system. Genie part number 29587. Part No. 29487 Genie Z-45/22 4 - 35...

  • Page 62: Check Engine Valve Clearance - Gasoline/Lpg Models

    Gasoline/LPG Models Complete information to perform this procedure is available in the Ford LSG-423 2.3 Litre Industrial Engine Service Manual (Ford number: 194-216). Genie part number 29586. Check Engine Cylinder Compression - Gasoline/LPG Models Complete information to perform this procedure is available in the Ford LSG-423 2.3 Litre Industrial...
  • Page 63 4 Dry both hoses and inspect them for cracks and damage. Replace the hoses if they are damaged. pivot plate bolt 2 Disconnect the 2 hoses from the PCV valve, then disconnect the 2 hoses from the engine. Part No. 29487 Genie Z-45/22 4 - 37...

  • Page 64: Check The Engine Nozzle Injection Pressure - Diesel Models

    Pressure - Diesel Models Complete information to perform this procedure is available in the Kubota V1702-B Diesel Engine Workshop Manual (Kubota code number: 97897- 00691). Genie part number 29587. Check Injection Timing - Diesel Models Complete information to perform this procedure is...
  • Page 65 Service Manual - First Edition Section 4 - Scheduled Maintenance Procedures Part No. 29487 Genie Z-45/22 4 - 39...
  • Page 66 Service Manual - First Edition Section 4 - Scheduled Maintenance Procedures 4 - 40 Genie Z-45/22 Part No. 29487...

  • Page 67: Engine Will Not Crank Over

    Crank Over Be sure the key switch is in the appropriate position. Be sure the emergency stop button is pulled up into the on position. Be sure the circuit breaker is not tripped. Part No. 29487 Genie Z-45/22 5 - 3...
  • Page 68 Be sure to check fuel levels and engine coolant level. Be sure the gasoline shut-off valve is in the on position. Perform these tests in gasoline mode. 5 - 4 Genie Z-45/22 Part No. 29487...
  • Page 69 Service Manual - First Edition Section 5 - Troubleshooting Flow Charts CHART 2 Part No. 29487 Genie Z-45/22 5 - 5...
  • Page 70 Service Manual - First Edition Section 5 - Troubleshooting Flow Charts CHART 2 5 - 6 Genie Z-45/22 Part No. 29487...
  • Page 71 Service Manual - First Edition Section 5 - Troubleshooting Flow Charts Chart 2A Engine Cranks Over But Will Not Start - Gasoline/LPG Models Continuation of “good spark” fault path from previous flow chart. Part No. 29487 Genie Z-45/22 5 - 7...
  • Page 72 Service Manual - First Edition Section 5 - Troubleshooting Flow Charts CHART 2A 5 - 8 Genie Z-45/22 Part No. 29487...
  • Page 73 Be sure to check fuel levels and engine coolant level. Be sure the diesel shut-off valve is in the on position. Be sure engine glow plugs operate normally, see Maintenance section. Part No. 29487 Genie Z-45/22 5 - 9...
  • Page 74 Service Manual - First Edition Section 5 - Troubleshooting Flow Charts CHART 3 5 - 10 Genie Z-45/22 Part No. 29487...

  • Page 75: Engine Choke Inoperative - Gasoline/Lpg Models

    Be sure choke solenoid plunger can be manually pushed into the solenoid and the linkage in turn rotates the choke plate linkage. Be sure fuel select switch is in the gasoline position. Part No. 29487 Genie Z-45/22 5 - 11...
  • Page 76 Service Manual - First Edition Section 5 - Troubleshooting Flow Charts CHART 4 5 - 12 Genie Z-45/22 Part No. 29487...

  • Page 77: Engine Will Not Start On Lpg, But Will Start On Gasoline

    Chart 6 Engine Will Not Start On LPG, But Will Start On Gasoline - Gasoline/LPG Models Be sure fuel select switch is switched to LPG. Be sure to check LPG fuel level. Part No. 29487 Genie Z-45/22 5 - 13...

  • Page 78: Gasoline/Lpg Models

    Gasoline, But Will Start on - Gasoline/LPG Models Be sure fuel select switch is switched to gasoline. Be sure to check gasoline fuel level. Be sure that engine choke is operating properly. 5 - 14 Genie Z-45/22 Part No. 29487...

  • Page 79: Engine High Idle Inoperative - Gasoline/Lpg Models

    Be sure throttle linkage from governor to carburetor is not binding, see Repair section. Be sure high idle can be achieved by grasping the governor actuator arm and momentarily pulling to throttle the carburetor. Part No. 29487 Genie Z-45/22 5 - 15...
  • Page 80 Service Manual - First Edition Section 5 - Troubleshooting Flow Charts CHART 8 5 - 16 Genie Z-45/22 Part No. 29487...

  • Page 81: Engine Low Idle Inoperative - Gasoline/Lpg Models

    If low idle operates on gasoline but not on LPG, see Repair section for LPG regulator adjustments. Be sure throttle linkage from governor to carburetor is not binding, see Repair section. Part No. 29487 Genie Z-45/22 5 - 17...

  • Page 82: Engine High Idle Inoperative - Diesel Models

    Be sure mechanical linkage from 2-speed to fuel injector pump is not binding or defective. Be sure PR2 relay and 2-speed solenoid grounding wires are free of corrosion and have full continuity to ground. 5 - 18 Genie Z-45/22 Part No. 29487...

  • Page 83: Engine Low Idle Inoperative - Diesel Models

    Service Manual - First Edition Section 5 - Troubleshooting Flow Charts Chart 11 Engine Low Idle Inoperative - Diesel Models Check if mechanical linkage from 2-speed solenoid to fuel injection pump is binding or defective. Part No. 29487 Genie Z-45/22 5 - 19...

  • Page 84: All Functions Inoperative, Engine Starts And Runs

    Service Manual - First Edition Section 5 - Troubleshooting Flow Charts Chart 12 All Functions Inoperative, Engine Starts and Runs 5 - 20 Genie Z-45/22 Part No. 29487...

  • Page 85: All Lift And Steer Functions Inoperative, Drive Functions Operational

    Be sure all grounding wires for the hydraulic manifold valves are free of corrosion and have full continuity to ground. Part No. 29487 Genie Z-45/22 5 - 21...

  • Page 86: Ground Controls Inoperative, Platform Controls Operate Normally

    Service Manual - First Edition Section 5 - Troubleshooting Flow Charts Chart 14 Ground Controls Inoperative, Platform Controls Operate Normally Be sure all other functions operate normally, including platform controls. 5 - 22 Genie Z-45/22 Part No. 29487...

  • Page 87: Platform Controls Inoperative, Ground Controls Operate Normally

    Service Manual - First Edition Section 5 - Troubleshooting Flow Charts Chart 15 Platform Controls Inoperative, Ground Controls Operate Normally Be sure all cables are in good condition with no kinks or abrasions. Part No. 29487 Genie Z-45/22 5 - 23...

  • Page 88: Secondary Boom Up Function Inoperative

    Auxiliary power can raise the boom if it is already raised above the drive limit switch. 5 - 24 Genie Z-45/22 Part No. 29487...
  • Page 89 Service Manual - First Edition Section 5 - Troubleshooting Flow Charts CHART 16 Part No. 29487 Genie Z-45/22 5 - 25...
  • Page 90 Service Manual - First Edition Section 5 - Troubleshooting Flow Charts CHART 16 5 - 26 Genie Z-45/22 Part No. 29487...

  • Page 91: Secondary Boom Down Function Inoperative

    See Repair section. If secondary boom down function operates normally from the platform controls but not from the ground controls, troubleshoot the ground control toggle switch. See Repair section. Part No. 29487 Genie Z-45/22 5 - 27...
  • Page 92 Service Manual - First Edition Section 5 - Troubleshooting Flow Charts CHART 17 5 - 28 Genie Z-45/22 Part No. 29487...

  • Page 93: Primary Boom Up Function Inoperative

    Auxiliary power can raise the boom if it is already raised above the drive limit switch. Part No. 29487 Genie Z-45/22 5 - 29...
  • Page 94 Service Manual - First Edition Section 5 - Troubleshooting Flow Charts CHART 18 5 - 30 Genie Z-45/22 Part No. 29487...

  • Page 95: Primary Boom Down Function Inoperative

    See Repair section. If primary boom down function operates normally from the platform controls but not from the ground controls, troubleshoot the ground control toggle switch. See Repair section. Part No. 29487 Genie Z-45/22 5 - 31...
  • Page 96 Service Manual - First Edition Section 5 - Troubleshooting Flow Charts CHART 19 5 - 32 Genie Z-45/22 Part No. 29487...

  • Page 97: Primary Boom Extend Function Inoperative

    See Repair section. If primary boom extend function operates normally from the platform controls but not from the ground controls, troubleshoot the ground control toggle switch. See Repair section. Part No. 29487 Genie Z-45/22 5 - 33...
  • Page 98 Service Manual - First Edition Section 5 - Troubleshooting Flow Charts CHART 20 5 - 34 Genie Z-45/22 Part No. 29487...

  • Page 99: Primary Boom Retract Function Inoperative

    See Repair section. If primary boom retract function operates normally from the platform controls but not from the ground controls, troubleshoot the ground control toggle switch. See Repair section. Part No. 29487 Genie Z-45/22 5 - 35...

  • Page 100: Turntable Rotate Function Inoperative

    See Repair section. If turntable rotate function operates normally from the platform controls but not from the ground controls, troubleshoot the ground control toggle switch. See Repair section. 5 - 36 Genie Z-45/22 Part No. 29487...
  • Page 101 Service Manual - First Edition Section 5 - Troubleshooting Flow Charts CHART 22 Part No. 29487 Genie Z-45/22 5 - 37...

  • Page 102: Turntable Rotate Left Function Inoperative

    See Repair section. If turntable rotate left function operates normally from the platform controls but not from the ground controls, troubleshoot the ground control toggle switch. See Repair section. 5 - 38 Genie Z-45/22 Part No. 29487...

  • Page 103: Turntable Rotate Right Function Inoperative

    See Repair section. If turntable rotate right function operates normally from the platform controls but not from the ground controls, troubleshoot the ground control toggle switch. See Repair section. Part No. 29487 Genie Z-45/22 5 - 39...

  • Page 104: All Platform Leveling Functions Inoperative

    Be sure all other functions operate normally. Be sure both automatic and manual platform leveling do not operate. If automatic leveling operates but manual leveling does not, troubleshoot Platform Leveling Up Function Inoperative . 5 - 40 Genie Z-45/22 Part No. 29487...

  • Page 105: Platform Level Up Function Inoperative

    See Repair section. If platform level up function operates normally from the platform controls but not from the ground controls, troubleshoot the ground control toggle switch. See Repair section. Part No. 29487 Genie Z-45/22 5 - 41...

  • Page 106: Platform Level Down Function Inoperative

    See Repair section. If platform level down function operates normally from the platform controls but not from the ground controls, troubleshoot the ground control toggle switch. See Repair section. 5 - 42 Genie Z-45/22 Part No. 29487...

  • Page 107: Platform Rotate Left Function Inoperative

    See Repair section. If platform rotate left function operates normally from the platform controls but not from the ground controls, troubleshoot the ground control toggle switch. See Repair section. Part No. 29487 Genie Z-45/22 5 - 43...

  • Page 108: Platform Rotate Right Function Inoperative

    See Repair section. If platform rotate right function operates normally from the platform controls but not from the ground controls, troubleshoot the ground control toggle switch. See Repair section. 5 - 44 Genie Z-45/22 Part No. 29487...

  • Page 109: Oscillate Lock-Out Function Inoperative

    Service Manual - First Edition Section 5 - Troubleshooting Flow Charts Chart 30 Oscillate Lock-out Function Inoperative Part No. 29487 Genie Z-45/22 5 - 45...

  • Page 110: Steer Left Function Inoperative

    Service Manual - First Edition Section 5 - Troubleshooting Flow Charts Chart 31 Steer Left Function Inoperative Be sure all other functions operate normally. Machines not equipped with oscillating axle, disregard the steer unloader valve troubleshooting. 5 - 46 Genie Z-45/22 Part No. 29487...

  • Page 111: Steer Right Function Inoperative

    Service Manual - First Edition Section 5 - Troubleshooting Flow Charts Chart 32 Steer Right Function Inoperative Be sure all other functions operate normally. Machines not equipped with oscillating axle, disregard the steer unloader valve troubleshooting. Part No. 29487 Genie Z-45/22 5 - 47...

  • Page 112: All Drive Functions Inoperative, All Other Functions Operate Normally

    Chart 33 All Drive Functions Inoperative, All Other Functions Operate Normally Be sure the hydraulic suction line valve is in the open position. Be sure machine is not in the free wheel configuration. 5 - 48 Genie Z-45/22 Part No. 29487...
  • Page 113 Service Manual - First Edition Section 5 - Troubleshooting Flow Charts CHART 33 Part No. 29487 Genie Z-45/22 5 - 49...

  • Page 114: Drive Forward Or Reverse Function Inoperative

    Service Manual - First Edition Section 5 - Troubleshooting Flow Charts Chart 34 Drive Forward Or Reverse Function Inoperative Be sure all other functions operate normally including drive in opposite direction of malfunction. 5 - 50 Genie Z-45/22 Part No. 29487...

  • Page 115: High Range Drive Function Inoperative

    Be sure all other functions operate normally including drive low range (four wheel symbol). Be sure all drive manifold solenoid valve grounding wires are free of corrosion and have full continuity to ground. Part No. 29487 Genie Z-45/22 5 - 51...
  • Page 116 Service Manual - First Edition Section 5 - Troubleshooting Flow Charts CHART 35 5 - 52 Genie Z-45/22 Part No. 29487...

  • Page 117: Low Range Drive Function Inoperative

    Service Manual - First Edition Section 5 - Troubleshooting Flow Charts Chart 36 Low Range Drive Function Inoperative Be sure all other functions operate normally including drive high range (two wheel symbol). Part No. 29487 Genie Z-45/22 5 - 53...

  • Page 118: Machine Will Not Drive At Full Speed

    Service Manual - First Edition Section 5 - Troubleshooting Flow Charts Chart 37 Machine Will Not Drive At Full Speed Be sure all other functions operate normally. 5 - 54 Genie Z-45/22 Part No. 29487...

  • Page 119: Schematics

    Do not allow oil to squirt Read, understand and obey the safety rules or spray. and operating instructions printed in the Genie General Repair Process Z-45/22 Operating Instruction Manual . Be sure that all necessary tools and test...

  • Page 120: Electrical Symbol Legend

    Tilt sensor no connection Single axis proportional Vacuum switch controller Relay contact Diode Spark plug normally open Oil pressure Relay panel Dual axis switch Glow plug contactor proportional normally closed Battery controller 6 - 2 Genie Z-45/22 Part No. 29487...
  • Page 128 6-10...
  • Page 129 6-11...
  • Page 130 6-12...

  • Page 131: Hydraulic Symbols Legend

    Solenoid operated 2 pos., Relief valve 3 way, directional valve Sequencing valve Bi-directional motor Priority flow divider 2-speed, bi-directional motor Pump prime mover Solenoid operated (engine or motor) dump valve Counterbalance valve Part No. 29487 Genie Z-45/22 6 - 3...
  • Page 132 Z45-22 Hyd. Index...
  • Page 133 Z45-22 Hyd. Index...
  • Page 134 Z45-22 Hyd. Index...
  • Page 135 Z45-22 Hyd. Index...
  • Page 136 Z45-22 Hyd. Index...
  • Page 137 Z45-22 Hyd. Index...
  • Page 138 Repair any machine damage or malfunction discovered symptoms before operating the machine. Before Repairs Start: problem still exists Read, understand and obey the safety rules and operating instructions printed in the Genie Return to Inspect Perform Z-45/22 Operating Instruction Manual . service and test repair...

  • Page 139: Platform Controls

    Emergency Stop button to the on position counterclockwise to decrease the voltage. at both the ground and platform controls. Do not start the engine. 3 Open the platform control box lid and locate the primary up/down controller. 7 - 2 Genie Z-45/22 Part No. 29487...
  • Page 140 5 turns. 5 Connect the red lead(+) from a volt meter to the “A” terminal on the controller PC board. Connect the black lead(-) to ground. Part No. 29487 Genie Z-45/22 7 - 3...
  • Page 141 "R" - activates max-out range terminal unused terminal "X" auxiliary terminal "-" - ground terminal "+" - battery, positive terminal "A" - proportional output threshold adjustable trimpot max-out adjustable trimpot 7 - 4 Genie Z-45/22 Part No. 29487...
  • Page 142 "+" - battery, positive position. Adjust the dual range trimpot to terminal "A" - proportional output achieve a 23 to 27 second cycle time. threshold adjustable trimpot max-out adjustable trimpot Part No. 29487 Genie Z-45/22 7 - 5...

  • Page 143: Horsepower Limiter Board

    2 Open the control box lid and locate the 71 to 75 second cycle time. horsepower limiter board. Specifications - Turntable Rotation function Threshold 3.35V DC Turntable rotation - 6.26V DC Max-out time 71-75 seconds 7 - 6 Genie Z-45/22 Part No. 29487...
  • Page 144 14 Drive the boom for 20 feet (6.1m) and record the elapsed time. Do this again in the opposite direction. 7 Move the engine speed control switch to low idle (turtle symbol). Part No. 29487 Genie Z-45/22 7 - 7...

  • Page 145: Foot Switch

    Desired result 3 Compare the ohmmeter reading with the continuity (zero Ω) red to black resistance rating printed on the resistor. no continuity (infinite Ω) red to white black to white no continuity 7 - 8 Genie Z-45/22 Part No. 29487...

  • Page 146: Toggle Switches

    3 to 4, 5 & 6 no continuity terminal 4 to 5 continuity terminal 4 to 6 no continuity terminal 5 to 6 no continuity Single pole, double throw (SPDT) Double pole, double throw (DPDT) Part No. 29487 Genie Z-45/22 7 - 9...

  • Page 147: Platform Components

    Do not allow oil to squirt or spray. 4 Remove the rod ends from both the barrel and rod end pins. 5 Use a soft metal drift and drive the pins out. 7 - 10 Genie Z-45/22 Part No. 29487...

  • Page 148: Platform Rotator

    9 Open the bleed valve and allow the slave cylinder to extend using gravity, until the cylinder is fully extended. Close the bleed valve. Part No. 29487 Genie Z-45/22 7 - 11...
  • Page 149 7 Rotate the platform to the right until it is centered. 8 Connect the clear hose to the bottom bleed valve and open the valve. 9 Rotate the platform to the right and continue 7 - 12 Genie Z-45/22 Part No. 29487...

  • Page 150: Primary Boom Components

    6 Extend and retract through the entire range of motion to check for tight spots that could cause binding. Always maintain squareness between the primary boom outer and inner tubes. Part No. 29487 Genie Z-45/22 7 - 13...
  • Page 151 Crushing hazard. If the overhead crane is not properly attached, the primary boom may become unbalanced and fall when it is disconnected from the upper mid-pivot. wood block tie-wrap plastic cable track 7 - 14 Genie Z-45/22 Part No. 29487...
  • Page 152 8 Remove the fasteners from the extension cylinder pivot pin. Use a soft metal drift to remove the pin. 9 Support and slide the extension boom out of Part No. 29487 Genie Z-45/22 7 - 15...

  • Page 153: Primary Boom Lift Cylinder

    Carefully lower the secondary boom onto the tube. block. Pay careful attention to the location and amount of shims used with each wear pad. upper mid-pivot 4x4x31 inch block counterweight 7 - 16 Genie Z-45/22 Part No. 29487...
  • Page 154 7 Support the primary lift cylinder with straps or ropes to restrict it from swinging freely. 8 Place a rod through the barrel-end pivot pin and twist to remove the pin. pivot pin 10 to 12 inch rod Part No. 29487 Genie Z-45/22 7 - 17...

  • Page 155: Extension Cylinder

    7 Disconnect and plug the extension cylinder counterweight hydraulic hoses. Cap the fittings on the cylinder. Crushing hazard. Keep hands away from the block and all moving parts when lowering the secondary boom. 7 - 18 Genie Z-45/22 Part No. 29487...

  • Page 156: Platform Leveling Master Cylinder

    Do not allow oil to squirt this procedure without these skills or spray. and tools may result in death or serious injury and significant component damage. Dealer service is strongly recommended. Before cylinder removal is Part No. 29487 Genie Z-45/22 7 - 19...
  • Page 157 11 Disconnect and plug the platform leveling master cylinder hydraulic hoses. Cap the 16 Carefully lower the platform leveling master fittings on the master cylinder. cylinder down and out of the upper mid-pivot. 7 - 20 Genie Z-45/22 Part No. 29487...

  • Page 158: Secondary Boom Components

    Follow the disassembly steps to the point required upper mid-pivot rest to complete the repair. Then re-assemble the upper mid-pivot secondary boom by following the disassembly steps in reverse order. Part No. 29487 Genie Z-45/22 7 - 21...
  • Page 159 9 Remove the pin retainers from the two secondary lift cylinder rod-end pivot pins. 10 Place a rod through each rod-end pivot pin and twist to remove the pins. 7 - 22 Genie Z-45/22 Part No. 29487...
  • Page 160 19 Number each electrical cable and its entry Crushing hazard. The upper location at the platform control box. mid-pivot will fall if it is not properly supported when the pivot pin is removed. Part No. 29487 Genie Z-45/22 7 - 23...
  • Page 161 42 Position the lifting strap from an overhead crane at the center of the number 3 arm. 7 - 24 Genie Z-45/22 Part No. 29487...
  • Page 162 47 Support the compression link by hand, then carefully lift the lower mid-pivot up and over the compression link and off of the machine. Part No. 29487 Genie Z-45/22 7 - 25...

  • Page 163: Secondary Boom Lift Cylinders

    Prior to removing the secondary lift cylinder, mark the location of the hydraulic fitting with a special internal orifice. Be sure to install the fitting into the same location during re-assembly. 7 - 26 Genie Z-45/22 Part No. 29487...

  • Page 164: Turntable Covers

    If a turntable cover must be replaced, be sure that all appropriate safety and instructional decals are applied to the new cover. Some adjustment may be necessary when a new cover is installed. Part No. 29487 Genie Z-45/22 7 - 27...

  • Page 165: Kubota V1702-B Engine

    2 Install the coupler onto the pump shaft with the Workshop Manual (Kubota code number: 97897- set screw towards the pump. Leave a 1/4 inch 00691). Genie part number 29587. (0.635mm) gap between the coupler and pump end plate. 3 Apply removable Loctite removable thread ®...
  • Page 166 Perform this procedure with the engine off. 1 Remove the 3 bolts from the engine pivot plate. Swing the engine pivot plate away from the machine to access both switches. pivot plate bolts Part No. 29487 Genie Z-45/22 7 - 29...

  • Page 167: Ford Lsg 423 Engine

    Rotate the actuator arm until it is at a 70 Tighten the fastener on the actuator arm degree angle to the linkage rod. without releasing the shaft. 7 - 30 Genie Z-45/22 Part No. 29487...

  • Page 168: Choke Adjustments

    Component damage hazard. During adjustments, do not allow the choke butterfly to stop the solenoid from fully retracting. The plunger must be able to bottom- out inside the solenoid housing. Part No. 29487 Genie Z-45/22 7 - 31...

  • Page 169: Timing Adjustment

    Secure the Engine Service Manual (Ford number: 194-216). bracket before continuing. Genie part number 29586. 6 Support the drive pump with an appropriate lifting device. Then remove all of the pump mounting plate to engine bell housing bolts.

  • Page 170: Water Temperature And Oil Pressure Switches

    Temperature switch point 230° F (112° C) Oil pressure switch Torque 8-18 foot-pounds 11-24 Newton meters Hex size 1-1/16 inch Oil pressure switch point 3-5 psi (0.21-0.34 bar) oil pressure switch water temperature switch Part No. 29487 Genie Z-45/22 7 - 33...

  • Page 171: Vacuum Switch

    (infinite Ω). 2 Apply mild suction to the vacuum port. Result: The switch should close and show full continuity (zero Ω). Component damage hazard. Do not short vacuum switch terminals to ground. 7 - 34 Genie Z-45/22 Part No. 29487...

  • Page 172: Ground Controls

    8 to 12 terminal 5 to 9 continuity terminal no. 5 terminal no. 1 relay terminal no. 13 terminal no. 9 terminal no. 12 terminal no. 14 terminal no. 4 terminal no. 8 Part No. 29487 Genie Z-45/22 7 - 35...

  • Page 173: Wago Components

    3 Use the provided screwdriver to gently pry up on the tab of the component and remove it. no continuity terminal 1 to 5 & 9 (infinite Ω) continuity (zero Ω) terminal 5 to 9 7 - 36 Genie Z-45/22 Part No. 29487...

  • Page 174: Resistors

    2 Connect the leads from an ohmmeter to each end or wiring of the resistor being tested. 3 Compare the ohmmeter reading with the resistance rating printed on the resistor. Part No. 29487 Genie Z-45/22 7 - 37...

  • Page 175: Relay Panel

    Terminals 85 to 86 terminal 87 to 30 represent the coil and should not be tested in any other combination. terminal no. 87A terminal no. 85 terminal no. 30 terminal no. 86 terminal no. 87 7 - 38 Genie Z-45/22 Part No. 29487...

  • Page 176: Power Relay

    2 Connect 12V DC to one of the small posts and ground to the other small post, then test the following terminal combination. Test Desired result continuity (zero Ω) 2 large posts Part No. 29487 Genie Z-45/22 7 - 39...

  • Page 177: Hydraulic Pumps

    The pump is good. tank valves after re-installing the Result: If pressure fails to reach 3000 psi pump. (206 bar), the pump is bad and will need to be replaced. 7 - 40 Genie Z-45/22 Part No. 29487...

  • Page 178: Drive Hydraulic Pump

    2 Crank the engine with the starter motor for 15 1 Disconnect the electrical connection at the seconds. electronic displacement controller (EDC) located on the main pump. 2 Close the two hydraulic tank valves located at the main pump. open closed Part No. 29487 Genie Z-45/22 7 - 41...

  • Page 179: Function Manifold

    Counterbalance valve ......AZ ..Platform leveling cylinder - retract ..10-12 ft-lbs / 15-18 Nm 3 position 4 way valve ....... E ... Platform rotate ........30-35 in-lbs / 3-4 Nm 7 - 42 Genie Z-45/22 Part No. 29487...
  • Page 180 Service Manual - First Edition Section 7 - Repair Procedures FUNCTION MANIFOLD Part No. 29487 Genie Z-45/22 7 - 43...

  • Page 181: Valve Adjustments

    Tip-over hazard. Do not adjust the Specifications relief valves higher than recommended. They are set to Relief valve pressure 1200 psi / 83 bar prevent a tip-over or damage to lift linkage. 7 - 44 Genie Z-45/22 Part No. 29487...
  • Page 182 Specifications direction of intended travel. Valve Resistance Proportional solenoid valve 5Ω 3 pos 4 way directional valve 4.5Ω 7Ω Normally closed poppet valve directional valves proportional valves function manifold Part No. 29487 Genie Z-45/22 7 - 45...

  • Page 183: Fuel And Hydraulic Tanks

    Burn hazard. Contact with hot oil may cause severe burns. 4 Disconnect the hydraulic hoses from the reservoir. 5 Remove the reservoir anchor hook from the back of the reservoir. 7 - 46 Genie Z-45/22 Part No. 29487...

  • Page 184: Fuel Tank

    5 Remove the mounting fasteners from the bottom of the tank. 6 Use an appropriate lifting device to remove the tank from the machine. Clean the fuel tank and inspect for rust and corrosion before it is installed. Part No. 29487 Genie Z-45/22 7 - 47...

  • Page 185: Turntable Rotation Components

    Do not allow the turntable to Crushing hazard. Do not remove rotate until the hydraulic motor is the 4x4x31 inch (78cm) support installed. block installed during primary boom removal. upper mid-pivot 4x4x31 inch block counterweight 7 - 48 Genie Z-45/22 Part No. 29487...
  • Page 186 7 Close the two hydraulic tank valves located at the main pump. Oscillating axle limit switch limit switch open closed oscillate lock-out wedge Part No. 29487 Genie Z-45/22 7 - 49...
  • Page 187 30 Loosen the counterweight positioning bolt. 31 Remove the fasteners from the counterweight. 32 Carefully lower the counterweight from the machine. 33 Remove the fasteners from the underside of the rotate bearing, then remove the rotate bearing. 7 - 50 Genie Z-45/22 Part No. 29487...
  • Page 188 2 Locate the “red” mark on the outside bearing race. Align the mark with the rotation stop block on the chassis. Specifications - torque First rotation 95 foot pounds 129 Newton meters Second rotation 190 foot pounds 258 Newton meters Part No. 29487 Genie Z-45/22 7 - 51...
  • Page 189 If it is, remove the turntable and grind the worm drive gear housing until clearance is established. 7 - 52 Genie Z-45/22 Part No. 29487...

  • Page 190: 2Wd Steering Axle Components

    4 Raise the machine and place blocks under the chassis. 5 Remove the lug nuts, then the tire and wheel assembly. 6 Remove the pin retainer attached to the king pin. Part No. 29487 Genie Z-45/22 7 - 53...

  • Page 191: Steering Cylinders

    3 Remove the steering cylinder. Always use a new cotter pin when 10 Install the dust cap, then the tire and wheel re-installing a clevis pin. assembly. Torque the wheel lug nuts to 125 foot-pounds (169Nm). 7 - 54 Genie Z-45/22 Part No. 29487...

  • Page 192: Tie Rod

    Front to front and back to back. 3 Center a jack under the steering axle, then raise the machine. 4 Loosen the jam nut on the adjustable end of the tie rod. Part No. 29487 Genie Z-45/22 7 - 55...

  • Page 193: 4Wd Steering Axle Components

    7 - 56 Genie Z-45/22 Part No. 29487...
  • Page 194 Perform the Tie Rod Toe-in Adjustment. 169 Newton meters 15-2 Steering Cylinders How to Remove the Steering Cylinder This procedure is the same as the 2WD procedure. See repair procedure 14-2, How to Remove the Steering Cylinder. Part No. 29487 Genie Z-45/22 7 - 57...

  • Page 195: Oscillating Axle Components

    Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 2 Remove the oscillation lock-out limit switches 7 - 58 Genie Z-45/22 Part No. 29487...

  • Page 196: Steer And Oscillate Manifold

    Normally closed poppet valve ... A ... Steering dump ........25-30 ft-lbs / 34-41 Nm 2 position 4 way valve ....... D ... Oscillate ..........10-12 ft-lbs / 14-16 Nm Check valve ........E ... Oscillate check ........35-40 ft-lbs / 47-54 Nm Part No. 29487 Genie Z-45/22 7 - 59...

  • Page 197: Valve Adjustments

    Do not allow oil to squirt or spray. 1 Start the engine and raise the primary boom above the drive limit switch. Do not lift the primary boom above the secondary boom. drive limit switch 7 - 60 Genie Z-45/22 Part No. 29487...

  • Page 198: Non-Steering Axle Components

    3 Slide the drive motor shaft out of the brake and Specifications then remove. Lug nut torque 125 foot-pounds On older machines, the drive 169 Newton meters motor and brake must be removed together. Part No. 29487 Genie Z-45/22 7 - 61...

  • Page 199: 2Wd Drive Manifold

    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 7 - 62 Genie Z-45/22 Part No. 29487...
  • Page 200 Service Manual - First Edition Section 7 - Repair Procedures 2WD DRIVE MANIFOLD Part No. 29487 Genie Z-45/22 7 - 63...

  • Page 201: Valve Adjustments

    6 Restart the engine. Drive the machine in either direction and recheck the valve pressure. 7 Turn the engine off, then remove the pressure gauge. Specifications Relief valve 320 psi / 22 bar 7 - 64 Genie Z-45/22 Part No. 29487...
  • Page 202 Service Manual - First Edition Section 7 - Repair Procedures 2WD DRIVE MANIFOLD This page intentionally left blank. Part No. 29487 Genie Z-45/22 7 - 65...

  • Page 203: 4Wd Drive Manifold

    Flow regulator valve ....G ....RF flow control in reverse ..10-12 ft-lbs / 14-16 Nm Flow regulator valve ....E ....RF flow control in forward ..10-12 ft-lbs / 14-16 Nm 7 - 66 Genie Z-45/22 Part No. 29487...
  • Page 204 Service Manual - First Edition Section 7 - Repair Procedures 4WD DRIVE MANIFOLD Part No. 29487 Genie Z-45/22 7 - 67...

  • Page 205: Valve Adjustments

    6 Restart the engine. Drive the machine in either direction and recheck the valve pressure. 7 Turn the engine off, then remove the pressure gauge. Specifications Relief valve 320 psi / 22 bar 7 - 68 Genie Z-45/22 Part No. 29487...

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