Genie Z45/25J Bi-Energy Service Manual Supplement
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Genie Z45/25J Bi-Energy Service Manual Supplement

Self-propelled servicing platform
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  • Page 2 107713 Rev B July 2011 http://www.genieindustries.com First Edition, Second Printing e-mail: awp.techpub@terex.com "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. Self-Propelled Servicing Platform Part No. 107713...
  • Page 3 Copyright © 2011 Terex Corporation 107713 Rev B July 2011 http://www.genielift.com First Edition, Second Printing e-mail: awp.techpub@terex.com "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.

  • Page 4: Table Of Contents

    Service Manual Supplement July 2011 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 ............

  • Page 5: Machine Specifications

    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. Self-Propelled Servicing Platform Part No. 107713...

  • Page 6: Hydraulic Specifications

    25 psi / 1.7 bar bypass Chevron Rykon MV oil is fully compatible and mixable with Shell Donax TG (Dexron III) oils. Function manifold Genie specifications require hydraulic oils which are designed to give maximum protection to hydraulic Function relief valve pressure 3200 psi systems, have the ability to perform over a wide 220.6 bar...
  • Page 7 Service Manual Supplement January 2006 SPECIFICATIONS REV A Kubota Z482-E Engine Injection system Injection pump make Bocsh MD Displacement 29.23 cu in 0.48 liters Injection timing 21° BTDC Number of cylinders Injection pump pressure 1991 psi 137 bar Bore and stroke 2.64 x 2.68 inches 67 x 68 mm Fuel requirement...

  • Page 8: Hydraulic Hose And Fitting Torque Specifications

    O-rings. or when new hoses or fittings are installed. They are not standard SAE size O-rings. They are available in the O-ring field service kit (Genie part SAE O-ring Boss Port number 49612). (tube fitting - installed into Aluminum) 2 Lubricate the O-ring before installation.
  • Page 9 Service Manual Supplement January 2006 This page intentionally left blank. Self-Propelled Servicing Platform Part No. 107713...

  • Page 10: Scheduled Maintenance Procedure

    Service Manual Supplement November 2011 Scheduled Maintenance Procedure 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. Observe and Obey: Symbols Legend Safety alert symbol—used to alert Maintenance inspections shall be completed by a personnel to potential personal person trained and qualified on the maintenance...

  • Page 11: Maintenance Inspection Report

    Service Manual Supplement November 2011 Maintenance Inspection Report Refer to the Genie Z-45/25 Bi-Energy & Z-45/25J Bi-Energy Service Model Manual for scheduled machine maintenance procedures. Serial number The following scheduled maintenance procedure will need to be performed every 1000 hours or annually in addition to regularly...

  • Page 12: Maintenance Procedure

    Note: Do not turn the machine off before removing the jumper from the back of the display. If the Note: Genie specifications require that this machine is turned off before the jumper wire is procedure be performed every 1000 hours of removed, all data may not save completely or operation or yearly.
  • Page 13 TYPE - Allows the choice of thermocouple being 6 Press the blank (unmarked) button to cycle used. Genie uses Type K thermocouples. through available choices for each menu item. 7 Press the button to make your choice and CJC - Cold Junction Compensation.
  • Page 14 Service Manual Supplement July 2011 REV B MAINTENANCE PROCEDURE How to Calibrate the 5 Use a precision DC voltage power supply with an output range of -10 mV DC to 60 mV DC and Temperature Sensor Voltage an accuracy of 0.03% or better. Connect the Input positive and negative leads of the power supply to the...
  • Page 15 Service Manual Supplement July 2011 MAINTENANCE PROCEDURE REV B 12 Exit the programming mode by removing the jumper wire from the back of the temperature display. Result: The display will show to indicate the SAVE programming changes are being saved into memory.
  • Page 16 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 menu item.
  • Page 17 Service Manual Supplement July 2011 This page intentionally left blank. Self-Propelled Servicing Platform Part No. 107713...

  • Page 18: Repair Procedures

    Read, understand and obey the safety rules an imminently hazardous situation and operating instructions in the which, if not avoided, will result in Genie Z-45/25 Bi-Energy & Genie Z-45/25J death or serious injury. Bi-Energy Operator’s Manual on your machine. Used to indicate the presence of a...

  • Page 19: Steer Axle Components

    Service Manual Supplement November 2011 Steer Axle Components REV B Yoke and Hub 2 Loosen the wheel lug nuts. Do not remove them. 3 Block the non-steer wheels, and then center a How to Remove the Yoke lifting jack of ample capacity under the steer axle.
  • Page 20 Service Manual Supplement November 2011 REV B STEERING AXLE COMPONENTS How to Remove the How to Install the Hub and Bearings Hub and Bearings 1 Loosen the wheel lug nuts. Do not remove Note: When replacing a wheel bearing, both the them.

  • Page 21: Tie Rod

    Service Manual Supplement November 2011 STEERING AXLE COMPONENTS REV B Steer Cylinders Tie Rod How to Remove a Steer Cylinder How to Remove the Tie Rod There are two identical steer cylinders that 1 Remove the cotter pins from the clevis pins at work in parallel.

  • Page 22: Non-Steer Axle Components

    Service Manual Supplement July 2011 Non-steer Axle Components REV B Drive Motor Torque Hub How to Remove a Drive Motor How to Remove a Drive Torque Hub 1 Disconnect the battery packs. Note: The drive motor must be removed in order to 2 Remove the fasteners from the cover on the non- access the torque hub mounting bolts.
  • Page 23 Service Manual Supplement July 2011 NON-STEER AXLE COMPONENTS REV B 7 Place a second lifting jack under the torque hub for support. Secure the torque hub to the lifting jack. 8 Remove the torque hub mounting bolts that attach the torque hub to the non-steer axle. 9 Remove the torque hub from the machine.

  • Page 24: Fiberglass Covers

    Service Manual Supplement July 2011 Fiberglass Covers REV A Repair or Replacement of a Fiberglass Cover Repair: Minor damage, including small holes, cracks and chips in a fiberglass cover may be repaired by a qualified repair facility. Replacement: Replacement of a fiberglass cover when the structural integrity has been compromised due to excessive damage is required.
  • Page 25 July 2011 This page intentionally left blank. Self-Propelled Servicing Platform Part No. 107713...

  • Page 26: Electrical Schematic

    Service Manual Supplement November 2011 Electrical Schematic...
  • Page 27 November 2011 Service Manual Supplement Electrical Schematic REV C C29JSH RD/WH C32JSL WH/RD C30FWD WH C31REV WH/BK C40LS OR RD-(FS) C9P-3 P25BAT RD BK-(FS) C7P-1 C9P-1 BK WH-(FS) C9P-2 P24BAT WH P24BAT WH P26BAT R42BAT OR/RD C132 PLI BL/WH HIGH FOOTSWITCH GLOW ENGINE...
  • Page 28 November 2011 Service Manual Supplement REV C Electrical Schematic C29JSH RD/WH C29JSH RD/WH C32JSL WH/RD C32JSL WH/RD LVI/BCI C30FWD WH C30FWD WH C31REV WH/BK C31REV WH/BK C40LS OR C40LS OR P24BAT WH P24BAT WH R42BAT OR/RD DP1 - JOYSTICK TURNTABLE SECONDARY PRIMARY PRIMARY...
  • Page 29 November 2011 Service Manual Supplement Electrical Schematic...

  • Page 30: Ground Control Box Terminal Strip Wiring Diagram

    November 2011 Service Manual Supplement Ground Control Box Terminal Strip Wiring Diagram...
  • Page 31 November 2011 Service Manual Supplement Ground Control Box Terminal Strip Wiring Diagram REV C BRN GND GR/BK H6 RD TS55 RD TS51 BK C7-1 BK 22B BL/WH C1-12 RD H6 BK-ALARM CR20 LIFT PUMP RELAY AUXILIARY POWER RELAY GR/WH GR/WH RD/WH RD/WH OR/RD...

  • Page 32: Ground Control Box Switch Panel Wiring Diagram

    November 2011 Service Manual Supplement REV C Ground Control Box Switch Panel Wiring Diagram BK/RD BK/RD-35A C45JSV GR/WH (C2B-7) GR/BK-18A BK-7A GR-17A BK/WH-8A WH/BK-5A GR/BK WH-4A RD-27A OR/BK-15A OR/BK RD/BK-2A OR-14A RD-1A GR/BK-44A RD C23-6 BK-22A P20BAT RD (C7B-4) BL-10A BL/BK-11A GR/WH-19A P20BAT RD (C5B-1)
  • Page 33 November 2011 Service Manual Supplement Ground Control Box Switch Panel Wiring Diagram...

  • Page 34: Platform Control Box Wiring Diagram

    November 2011 Service Manual Supplement Platform Control Box Wiring Diagram...
  • Page 35 November 2011 Service Manual Supplement Platform Control Box Wiring Diagram REV C COMPONENT INDEX PLATFORM CONTROL BOX ROTARY FLOW CONTROL DIAL DRIVE JOYSTICK BRN-RELAY DRIVE ENABLE LED EMERGENCY STOP HORN AUXILIARY SWITCH ENGINE START TOGGLE SWITCH HIGH / LOW RPM TOGGLE SWITCH GLOW PLUG TOGGLE SWITCH PLATFORM ROTATE TOGGLE SWITCH JIB BOOM UP / DOWN SWITCH...

  • Page 36: Platform Control Box Switch Panel Wiring Diagram

    November 2011 Service Manual Supplement REV C Platform Control Box Switch Panel Wiring Diagram LVI/BCI Options COMPONENT INDEX PLATFORM CONTROL BOX BATTERY CHARGE INDICATOR OR/RD ROTARY FLOW CONTROL DIAL WH P24 BAT DRIVE JOYSTICK CR51 OR/BK DRIVE ENABLE LED OR/RD LOAD SENSE LED RESET IS SET TO "B", LOW VOLTAGE INTERRUPT MODULE...
  • Page 37 November 2011 Service Manual Supplement Platform Control Box Switch Panel Wiring Diagram LVI/BCI Options...

  • Page 38: Engine Panel Diagram

    November 2011 Service Manual Supplement Engine Panel Diagram...
  • Page 39 November 2011 Service Manual Supplement Engine Panel Diagram REV C RD-CB CIRCUT BREAKER NOTE: RELAY SOCKETS ARE SHOWN FROM THE RELAY SOCKET SIDE. 12V DC, 15A RD-CB (12V+) C21IGN2 WH C21IGN2 WH C35HRPM BK/RD C35HRPM BK/RD WH-J5 WH-J5 BRN-J4 BRN-J4 BRN-J4 BRN-J4 BRN-J4...

  • Page 40: Power Cable Diagram

    November 2011 Service Manual Supplement REV C Power Cable Diagram TO ENGINE PANEL TO GROUND CONTROL BOX CONNECTOR C6 AC POWER CABLE LEFT SIDE DC AMMETER CABLE BATTERY PACK RIGHT SIDE RD-2GA BATTERY PACK ALTERNATOR BATTERY CHARGER PRIMARY RD-2GA LIFT PUMP AUXILIARY LIFT PUMP...
  • Page 41 November 2011 Service Manual Supplement Power Cable Diagram...

  • Page 42: Hydraulic Schematic

    November 2011 Service Manual Supplement REV C Hydraulic Schematic JIB BOOM PLATFORM ROTATE 1.5:1 3000 psi / 3800 psi / 207 bar 262 bar 0.020 inch / 0.020 inch / 0.51 mm 0.51 mm JIB BOOM MANIFOLD SECONDARY BOOM SLAVE CYLINDER PRIMARY BOOM TURNTABLE ROTATE EXTENSION CYLINDER...
  • Page 43 November 2011 Service Manual Supplement Hydraulic Schematic...
  • Page 44 Genie North America Phone 425.881.1800 Toll Free USA and Canada 800.536.1800 425.883.3475 Genie Holland Genie Australia Pty Ltd. Phone + Phone + 31 70 51 78836 61 7 3375 1660 Fax + Fax + 31 70 51 13993 61 7 3375 1002...

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