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Service and Repair Manual Serial Number Range -45/25 DC ® from Z452513A-48153 This manual includes: to Z452516N-57199 Repair procedures -45/25J DC ® from Z452513B-3078 Fault Codes to Z452516M-6699 Electrical and from Z452513D-101 Hydraulic Schematics to Z452516D-939 from Z4525D-940 to Z4525D-3977 from Z4524M-6700 to Z4525M-9726 For detailed maintenance...
May 2022 Service and Repair Manual Introduction Revision History Revision Date Section Procedure / Page / Description 9/2015 Initial Release 9/2016 Introduction Serial Number Legend 9/2016 Repair 10-1 11/2017 Specifications Machine Specifications 5/2022 Front cover Add ending serial break Reference Examples: Electronic Version Section –...
Service and Repair Manual May 2022 Introduction Serial Number Legend To August 31, 2016 1 Model 4 Sequence number 2 Model year 5 Serial label (located under cover) 3 Facility code 6 Serial number (stamped on chassis) From September 1, 2016 1 Model 4 Serial label (located under cover) 2 Facility code...
May 2022 Service and Repair Manual Safety Rules Secti on 1 Safety Rul es Danger Failure to obey the instructions and safety rules in this manual and the appropriate Operator's Manual on your machine 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...
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Service and Repair Manual May 2022 Safety Rules Personal Safety Workplace Safety Any person working on or around a machine Any person working on or around a machine must be aware of all known safety hazards. must be aware of all known safety hazards. Personal safety and the continued safe Personal safety and the continued safe operation of the machine should be your top...
May 2022 Table of Contents Introduction Introduction ...................... ii Important Information ..................ii Find a Manual for this Model ................ii Revision History ....................iii Serial Number Legend ..................iv Section 1 Safety Rules ...................... v General Safety Rules ..................v Section 2 Specifications ....................
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May 2022 Table of Contents Section 3 Repair Procedures ..................11 Introduction ...................... 11 Platform Controls ................... 13 1-1 Controllers ....................13 Platform Components ..................15 2-1 Bellcrank Platform Leveling Cylinder ............15 How to Bleed the Platform Leveling Cylinder ..........16 2-2 Platform Rotator ..................
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May 2022 Table of Contents Manifolds ......................42 7-1 Function Manifold Components ..............42 7-2 Valve Adjustments - Function Manifold ............44 How to Adjust the System Relief Valve ............44 How to Adjust the Secondary Boom Down Relief Valve ....... 44 7-3 Jib Boom / Platform Rotate Manifold Components ........
Service and Repair Manual May 2022 Specifications Hydraulic Oil Specifications Do not top off with incompatible hydraulic fluids. Hydraulic fluids may be incompatible due to the Hydraulic Fluid Specifications differences in base additive Genie specifications require hydraulic oils which are chemistry.
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May 2022 Service and Repair Manual Specifications Chevron Rando HD Premium Oil Chevron 5606A Hydraulic Oil MV Fluid Properties Fluid Properties ISO Grade ISO Grade Viscosity index Viscosity index Kinematic Viscosity Kinematic Viscosity cSt @ 200°F / 100°C cSt @ 200°F / 100°C cSt @ 104°F / 40°C cSt @ 104°F / 40°C 15.0...
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Service and Repair Manual May 2022 Specifications Petro-Canada Environ MV 46 UCON Hydrolube HP-5046 Fluid Fluid Properties Properties ISO Grade ISO Grade Viscosity index Viscosity index Kinematic Viscosity Kinematic Viscosity cSt @ 200°F / 100°C cSt @ 149°F / 65°C cSt @ 104°F / 40°C cSt @ 104°F / 40°C 44.4...
Service and Repair Manual May 2022 Specifications Machine Torque Specifications Machine Component Weights Platform Rotator Primary boom assembly 950 lbs 431 kg (does not include jib assembly) 3/4 -10 center bolt, GR 8 380 ft-lbs 515 Nm Secondary boom assembly 1675 lbs 760 kg 3/8 -16 bolts, GR 8...
May 2022 Service and Repair Manual Specifications Hydraulic Hose and Fitting Torque Specifications SAE O-ring Boss Port (tube fitting - installed into Aluminum) Your machine is equipped with Parker Seal-Lok™ (all types) ORFS or 37° JIC fittings and hose ends. Genie SAE Dash Size Torque specifications require that fittings and hose ends...
Service and Repair Manual May 2022 Specifications Torque Procedure JIC 37° fittings Align the tube flare (hex nut) against the nose Seal-Lok™ fittings of the fitting body (body hex fitting) and tighten the hex nut to the body hex fitting to Replace the O-ring.
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May 2022 Service and Repair Manual Specifications Working clockwise on the body hex fitting, make a second mark with a permanent ink marker to indicate the proper tightening position. Refer to Illustration 2. Note: Use the JIC 37° Fitting table in this section to determine the correct number of flats, for the proper tightening position.
May 2022 Service and Repair Manual Repair Procedures Machine Configuration: Secti on 3 Repair P roce dur es Unless otherwise specified, perform each repair procedure with the machine in the following configuration: • Machine parked on a firm, level surface •...
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Service and Repair Manual May 2022 Repair Procedures About This Section Most of the procedures in this section should only be performed by trained service professional in a suitably equipped workshop. Select the appropriate repair procedure after troubleshooting the problem. Perform disassembly procedures to the point where repairs can be completed.
May 2022 Service and Repair Manual Platform Controls Boom Function Speed Controller Adjustments Controllers Electrocution/burn hazard. The drive joystick is connected to the drive motor Contact with electrically charged controller located under the non-steer end drive circuits could result in death or chassis cover.
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Service and Repair Manual May 2022 Platform Controls Disconnect the blk/red wire of the boom function speed controller from the wht/red wire. Connect the red (+) lead from an amp meter to the blk/red wire. Connect the black (-) lead to the wht/red wire.
May 2022 Service and Repair Manual Platform Components Tag, disconnect and plug the hydraulic hoses from the leveling cylinder at the unions and Bellcrank Platform Leveling connect them together using a connector. Cylinder Connect the hoses from the cylinder together using a connector.
Service and Repair Manual May 2022 Platform Components How to Blee d th e Platf orm Lev eling Cylin der How to Bleed the Platform Use a soft metal drift to drive the rod-end pivot pin out. Leveling Cylinder Crushing hazard. The platform Note: This procedure will have to be preformed could fall when the leveling outside.
May 2022 Service and Repair Manual Platform Components While still holding the function enable toggle switch, simultaneously activate the primary Platform Rotator boom down and platform level down toggle switches until the primary boom is fully lowered. How to Bleed the Platform The platform should be facing in a down Rotator position.
Service and Repair Manual May 2022 Platform Components Move the function enable toggle switch to either side and hold the platform rotate toggle Platform Overload System switch to the right position until the platform is fully rotated to the right. Continue holding the toggle switch until air stops coming out of the How to Calibrate the Platform bleed screw.
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May 2022 Service and Repair Manual Platform Components Move the platform up and down by hand, so it Move the platform up and down by hand, so it bounces approximately 2.5 to 5 cm / 1 to bounces approximately 2.5 to 5 cm / 1 to 2 inches.
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Service and Repair Manual May 2022 Platform Components 10 Test all machine functions from the platform controls. Result: All platform control functions should not operate. 11 Turn the key switch to ground control. 12 Test all machine functions from the ground controls.
May 2022 Service and Repair Manual Jib Boom Components Use a soft metal drift to remove the platform rotator pivot pin and remove the platform Jib Boom rotator from the machine. 10 Slide both of the jib boom leveling arms off of How to Remove the Jib Boom the jib boom cylinder rod-end pivot pin.
Service and Repair Manual May 2022 Jib Boom Components 18 Attach a lifting strap from an suitable lifting device to the lug on the rod end of the jib Jib Boom Lift Cylinder boom lift cylinder. 19 Use a soft metal drift to remove the jib boom How to Remove the Jib Boom Lift lift cylinder rod-end pivot pin, then remove the jib boom lift cylinder from the bellcrank.
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May 2022 Service and Repair Manual Jib Boom Components Support the jib boom lift cylinder with a suitable lifting device. Remove the pin retaining fastener from the jib boom lift cylinder barrel-end pivot pin. Use a soft metal drift to remove the barrel-end pin and let the cylinder hang down.
Service and Repair Manual May 2022 Primary Boom Components Tag, disconnect and plug the hydraulic hoses from the "PR1" and "PR2" ports on the Cable Track counterbalance valve manifold located on the platform rotator. Cap the fittings on the The primary boom cable track guides the cables manifold.
May 2022 Service and Repair Manual Primary Boom Components 10 Place blocks in between the upper and lower How to Re mov e th e Cabl e T rack, Z- 45/ 25J How to Remove the Cable Track, cable tracks and secure the upper and lower Z-45/25J tracks together.
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Service and Repair Manual May 2022 Primary Boom Components Tag and disconnect the hydraulic hoses from 12 Place blocks between the upper and lower the platform leveling slave cylinder at the cable tracks and secure the upper and lower union and connect them together using a tracks together.
May 2022 Service and Repair Manual Primary Boom Components 23 Remove the mounting fasteners from the How to Re pair the P rima ry Boo m Ca ble Track How to Repair the Primary Boom upper cable track at the platform end of the Cable Track extension boom.
Service and Repair Manual May 2022 Primary Boom Components Remove the pin retaining fastener from the upper pivot platform leveling cylinder barrel- Primary Boom end pivot pin. Use a soft metal drift to remove the pin. Then lower the cylinder and let it hang How to Remove the Primary down.
May 2022 Service and Repair Manual Primary Boom Components 17 Remove the pin retaining fasteners from the How to Disa ssem ble t he Pri mary Boom How to Disassemble the Primary primary boom lift cylinder rod-end pivot pin. Boom Use a soft metal drift to remove the pin.
Service and Repair Manual May 2022 Primary Boom Components Remove the external snap rings from the extension cylinder rod-end pivot pin at the Primary Boom Lift Cylinder platform end of the extension tube. Use a soft metal drift to remove the pin. The primary boom lift cylinder raises and lowers Support and slide the extension cylinder out the primary boom.
May 2022 Service and Repair Manual Primary Boom Components Tag, disconnect and plug the primary boom lift cylinder hydraulic hoses. Cap the fittings Primary Boom Extension on the cylinder. Cylinder Bodily injury hazard. Spraying hydraulic oil can penetrate and The primary boom extension cylinder extends and burn skin.
Service and Repair Manual May 2022 Primary Boom Components Tag, disconnect and plug the primary boom extension cylinder hydraulic hoses. Cap the Upper Pivot Platform Leveling fittings on the cylinder. Cylinder Bodily injury hazard. Spraying hydraulic oil can penetrate and The upper pivot platform leveling cylinder acts as a burn skin.
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May 2022 Service and Repair Manual Primary Boom Components Remove the pin retaining fastener from the rod-end pivot pin. Place a rod through the rod-end pivot pin and twist to remove the pin. Remove the leveling cylinder from the machine. Crushing hazard.
May 2022 Service and Repair Manual Secondary Boom Components Tag, disconnect and plug the hydraulic hoses at the primary boom lift cylinder. Cap the Secondary Boom fittings on the cylinder. Bodily injury hazard. Spraying How to Disassemble the hydraulic oil can penetrate and Secondary Boom burn skin.
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Service and Repair Manual May 2022 Secondary Boom Components 13 Use a soft metal drift to drive the rod-end 21 Using a suitable lifting device attached to the pivot pin half way out. upper pivot, raise the secondary boom assembly approximately 30 inches / 76 cm. 14 Remove the secondary boom lift cylinder from the machine.
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May 2022 Service and Repair Manual Secondary Boom Components 29 Raise the number 2 arm slightly and remove 39 Use a soft metal drift to remove the upper the 4 x 4 x 11 inch / 10 x 10 x 28 cm block. compression link pivot pin from the number 2 arm.
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Service and Repair Manual May 2022 Secondary Boom Components 45 Using an approved hand-operated pump, 51 Remove the mounting fasteners from the drain the fuel tank into a container of suitable cover located in the boom storage area to capacity. Refer to Specifications, Machine access the number 3 and number 4 arm pivot pin retaining fasteners at the turntable riser.
May 2022 Service and Repair Manual Secondary Boom Components Remove the pin retaining fasteners from the secondary boom lift cylinder rod-end pivot pin Secondary Boom Lift Cylinder and barrel-end pivot pin. Do not remove the pins. There are two secondary boom lift cylinders Attach a strap from an suitable lifting device to incorporated in the structure of the secondary the lug on the rod end of the secondary boom...
Service and Repair Manual May 2022 Hydraulic Pump Models without hydraulic tank shutoff valves: Remove the drain plug from the Auxiliary Pump hydraulic tank and completely drain the tank into a container of suitable capacity. Refer to Specifications, Machine Specifications. How to Remove the Auxiliary Bodily injury hazard.
May 2022 Service and Repair Manual Hydraulic Pump Models without hydraulic tank shutoff valves: Remove the drain plug from the Function Pump hydraulic tank and completely drain the tank into a container of suitable capacity. Refer to Specifications, Machine Specifications. How to Remove the Function Pump Bodily injury hazard.
Service and Repair Manual May 2022 Manifolds Function Manifold Components The function manifold is located next to the hydraulic tank underneath the ground controls side cover. Index Schematic Description Function Torque Item Solenoid Valve, 2 position 3 way Primary boom retract 20 ft-lbs / 27 Nm Solenoid valve, 3 position 4 way Primary boom up/down...
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May 2022 Service and Repair Manual Manifolds Part No. 1268530GT ® -45/25 DC...
Service and Repair Manual May 2022 Manifolds 7-2 Valve Adjustments - Function How to Adju st th e Seco nda ry Boo m Dow n Relief Valve How to Adjust the Secondary Manifold Boom Down Relief Valve Note: Perform this procedure with the boom in the How to Adju st th e Syste m Relie f Valve How to Adjust the System Relief stowed position.
May 2022 Service and Repair Manual Manifolds Jib Boom / Platform Rotate Manifold Components The jib boom / platform rotate manifold is mounted to the platform support. Index Schematic Description Function Torque Item Solenoid valve, 2 position 3 way Jib boom / platform rotate select 20 ft-lbs / 27 Nm Part No.
Service and Repair Manual May 2022 Manifolds Turntable Rotation Manifold Components The turntable rotation manifold is mounted to the turntable rotation motor located in the boom storage compartment. Schematic Index No. Description Function Torque Item Counterbalance valve Turntable rotate right 30-35 ft-lbs / 41-47 Nm Counterbalance valve Turntable rotate left...
May 2022 Service and Repair Manual Manifolds Valve Coils How to Test a Coil A properly functioning coil provides an electromotive force which operates the solenoid valve. Critical to normal operation is continuity within the coil that provides this force field. Electrocution/burn hazard.
Service and Repair Manual May 2022 Turntable Rotation Components Tag, disconnect and plug the fuel hoses from the fuel tank. Turntable Rotation Assembly 10 Remove the fuel tank strap fasteners and remove the tank strap. How to Remove the Turntable 11 Remove the fuel tank from the machine.
May 2022 Service and Repair Manual Motor Controllers Set an ohmmeter to diode test mode. Motor Controller Connect the leads from an ohmmeter to test each motor controller terminal combination The drive motor controller is located under the listed below and check the forward / reverse non-steer end drive chassis cover.
Service and Repair Manual May 2022 Steer Axle Components How to I nstall t he Hu b a nd Bea rings How to Install the Hub and 10-1 Hub and Bearings Bearings How to Re mov e th e Hub and Beari ngs How to Remove the Hub and Note: When replacing a wheel bearing, both the Bearings...
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May 2022 Service and Repair Manual Steer Axle Components Loosen the castle nut one full turn and then torque to 35 ft-lbs / 47 Nm. 10 Install a new cotter pin. Bend the cotter pin to lock it in place. Note: Always use a new cotter pin when installing a castle nut.
Service and Repair Manual May 2022 Fault Codes Before Troubleshooting: Secti on 4 Fault C odes Read, understand and obey the safety rules and operating instructions in the appropriate operator's manual on your machine. Be sure that all necessary tools and test ...
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May 2022 Service and Repair Manual Fault Codes Fault Codes The controller status indicator light will flash a fault code to aid in troubleshooting. This indicator light is mounted on the left side of the ground control box. Fault codes are two digits. The controller status indicator light will blink the first digit of a two digit code, pause for 1 second, and then blink the second digit.
Service and Repair Manual May 2022 Fault Codes Fault C ode Cha rts Fault Code Chart Fault Code Programmer Condition Possible Causes Solution Diagnostic Display Fault code LED COMMUNICATION Machine will not drive. The key switch or Push in the ground is off or is on, ERROR Emergency Stop...
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May 2022 Service and Repair Manual Fault Codes Fault Code Chart Fault Code Programmer Condition Possible Causes Solution Diagnostic Display Open in wht/red wire THROTTLE FAULT 1 Machine will not drive. Consult Genie Product #32 at pin 14 or Support. red/wht wire #29 at pin 16 on the motor controller going from...
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Service and Repair Manual May 2022 Fault Codes Fault Code Chart Fault Code Programmer Condition Possible Causes Solution Diagnostic Display MISSING Motor controller does Consult Genie Product Machine will not drive. CONTACTOR not detect the main Support. contactor PR1 or brake release relay CR5.
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May 2022 Service and Repair Manual This page intentionally left blank. Part No. 1268530GT ® -45/25 DC...
Service and Repair Manual May 2022 Schematics About This Section Secti on 5 Schematic s There are two groups of schematics in this section. Electrical Schematics Electrocution/burn hazard. Contact with electrically charged Observe and Obey: circuits could result in death or serious injury.
May 2022 Service and Repair Manual Electrical Symbol Legend Battery Coil, solenoid or relay Horn or alarm Flashing beacon Gauge Diode Hour meter Fuse with amperage Foot switch T-circuits connect Limit switch Power relay Coil with suppression Fuel or RPM solenoid T-circuits connect at Circuits crossing no Quick disconnect...
Service and Repair Manual May 2022 Platform Control Box Wiring Diagram, (CE) Z®-4 5/25 DC Part No. 126 853 0GT Service a nd Re pair Ma nual May 2 022 Z®-4 5/25 J DC ® -45/25 DC Part No. 1268530GT...
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