Technical

Publications

Z- 45 22

Service
Manual

First Edition
Part No. 29487

Service Manual - First Edition

Introduction

Important
Read, understand and obey the safety rules and
operating instructions in the Genie Z-45/22
Operating Instruction Manual before attempting
any maintenance or repair procedure.
This service manual covers the Genie Z-45/22
2WD and 4WD models introduced in 1991.
This manual provides detailed scheduled
maintenance information for the machine owner
and user. It also provides troubleshooting and
repair procedures for qualified service
professionals.

Genie U.S.A. and Canada

Telephone (206) 881-1800
Toll Free 800 536-1800
Fax (206) 883-3475
Telex 152351

Genie Europe
Telephone (44) 0636-813943
Fax (44) 0636-815270

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 a Genie dealer service center.
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 other manuals. Please
write to the technical publications team in care of
Genie Industries, PO Box 69, Redmond WA
98073-0069 USA.
If you have any questions, call Genie Industries.

ii

Genie Z-45/22

Copyright 1992 by Genie Industries

First Edition, October 1992
Genie is a registered trademark
of Genie Industries
Registered 2009987
Printed on recycled paper
Printed in U.S.A.

Part No. 29487

Service Manual - First Edition

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
instruction 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:
- manufacturers instructions and safety rules
- employers safety rules
- applicable governmental regulations
You have the appropriate tools, lifting
equipment and a suitable workshop.

Part No. 29487

Genie Z-45/22

iii

Service Manual - First Edition

Section 1 - Safety Rules

SAFETY RULES

Personal Safety

Workplace 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 number one priority.

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.

Read each procedure thoroughly. This

manual and the decals, on the machine,
use signal words to identify the following:
Indicates the presence of
a hazard that will cause
death or serious injury.

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.

Indicates the presence of

a hazard that may cause
death or serious injury.
Indicates the presence of
a hazard that will or may
cause serious injury or
damage to the machine.
Indicates special
operation or maintenance
information.

Be sure to wear protective eye wear and

other protective clothing if the situation
warrants it.

Be sure that your workshop or work area

is well ventilated and safely and
adequately illuminated.

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 aware of potential crushing hazards

such as moving parts, free swinging or
unsecured components, and lifting or
placing loads. Always wear approved steel-toed
shoes.

iv

Genie Z-45/22

Be sure to properly dispose of old oil or

other fluids. Use an approved container.
Please be mindful of the environment.

Part No. 29487

Service Manual - First Edition

Table of Contents
Introduction
Important Information ..................................................................................................... ii
Section One

Safety Rules
General Safety Rules .................................................................................................... iii

Section Two

Specifications
Machine Specifications ............................................................................................. 2 - 1
Performance Specifications ...................................................................................... 2 - 2
Hydraulic Specifications ........................................................................................... 2 - 2
Ford LSG 423 Engine Specifications ........................................................................ 2 - 5
Kubota V1702-B Engine Specifications .................................................................... 2 - 7

Section Three

Scheduled Maintenance Inspections

Introduction ............................................................................................................... 3 - 1
Table A ..................................................................................................................... 3 - 2
Table B ..................................................................................................................... 3 - 3
Table C ..................................................................................................................... 3 - 4
Table D ..................................................................................................................... 3 - 5
Maintenance Inspection Report ................................................................................ 3 - 6

Section Four

Scheduled Maintenance Procedures

Introduction ............................................................................................................... 4 - 1

Part No. 29487

A-1

Inspect the Operating Instruction and Safety Manuals ................................... 4 - 2

A-2

Inspect the Decals and Placards .................................................................... 4 - 2

A-3

Inspect for Damage, Loose or Missing Parts .................................................. 4 - 2

A-4

Check the Engine Oil Level............................................................................. 4 - 3

A-5

Check the Engine Coolant Level ..................................................................... 4 - 3

A-6

Check for Fuel Leaks ...................................................................................... 4 - 3

A-7

Check the Hydraulic Oil Level ......................................................................... 4 - 4

A-8

Check for Hydraulic Leaks .............................................................................. 4 - 4

A-9

Check Tire Pressure ....................................................................................... 4 - 4

Genie Z-45/22

Service Manual - First Edition

TABLE OF CONTENTS

Section Four

Scheduled Maintenance Procedures, continued

A-10 Test the Platform and Ground Controls .......................................................... 4 - 5
A-11 Test Auxiliary Power Operation ...................................................................... 4 - 5
A-12 Test the Tilt Level Sensor ............................................................................... 4 - 6
A-13 Test the Limit Switches ................................................................................... 4 - 6
A-14 Replace the Engine Oil and Filter ................................................................... 4 - 8
A-15 Change the Engine Air Filter ........................................................................... 4 - 9
A-16 Drain the Fuel Filter/Water Separator - Diesel Models ................................. 4 - 10
B-1

Check the Engine Fan Belts ......................................................................... 4 - 11

B-2

Check the Radiator ....................................................................................... 4 - 11

B-3

Check the Exhaust System .......................................................................... 4 - 11

B-4

Check the Battery ......................................................................................... 4 - 12

B-5

Check the Hydraulic Reservoir Filter Condition Indicator .............................. 4 - 12

B-6

Inspect Electrical Wiring ............................................................................... 4 - 13

B-7

Inspect the Tires and Wheels ....................................................................... 4 - 13

B-8

Confirm Proper Brake Configuration ............................................................. 4 - 14

B-9

Check the Oil Level in the Torque Hubs ....................................................... 4 - 14

B-10 Check the Engine Choke - Gasoline/LPG Models ........................................ 4 - 15

B-11 Check the Glow Plugs - Diesel Models ......................................................... 4 - 15
B-12 Check and Adjust the Engine Idle Mixture - Gasoline/LPG Models .............. 4 - 16
B-13 Check and Adjust the Engine RPM............................................................... 4 - 16
B-14 Test the Key Switch ...................................................................................... 4 - 17
B-15 Test the Emergency Stop Buttons ................................................................ 4 - 18
B-16 Test the Ground Control Override ................................................................ 4 - 18
B-17 Test the Oscillate Lock-out ........................................................................... 4 - 18
B-18 Test Platform Self-leveling ............................................................................ 4 - 19
B-19 Test the Service Horn ................................................................................... 4 - 19
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

vi

Genie Z-45/22

Part No. 29487

Service Manual - First Edition

TABLE OF CONTENTS

Section Four

Scheduled Maintenance Procedures, continued

B-24 Test the Drive Enable System ...................................................................... 4 - 21
B-25 Test the Drive Brakes ................................................................................... 4 - 22
B-26 Test Drive Speed - Stowed Position ............................................................. 4 - 22
B-27 Test the Alarm Package (optional equipment) .............................................. 4 - 23
C-1

Check the Primary Boom Wear Pads ........................................................... 4 - 24

C-2

Check the Turntable Rotation Bearing Bolts ................................................. 4 - 24

C-3

Check the Free-wheel Feature ..................................................................... 4 - 25

C-4

Grease the Worm Drive Gear ....................................................................... 4 - 26

C-5

Replace the Torque Hub Oil ......................................................................... 4 - 27

C-6

Replace the Hydraulic Reservoir Filter ......................................................... 4 - 27

C-7

Replace the Drive Loop Hydraulic Filter ....................................................... 4 - 28

C-8

Replace the Diesel Fuel Filter ....................................................................... 4 - 28

C-9

Replace the Gasoline Fuel Filter ................................................................... 4 - 29

C-10 Replace the PCV Valve - Gasoline/LPG Models .......................................... 4 - 30

C-11 Clean or Replace the Distributor Cap and Rotor - Gasoline/LPG Models ..... 4 - 30
C-12 Replace the Spark Plugs - Gasoline/LPG Models ........................................ 4 - 31
C-13 Check and Adjust the Air/Propane Mixture - Gasoline/LPG Models ............. 4 - 31
C-14 Check and Adjust the Ignition Timing - Gasoline/LPG Models ..................... 4 - 32

Part No. 29487

D-1

Change The Hydraulic Oil ............................................................................. 4 - 33

D-2

Change or Recondition the Engine Coolant .................................................. 4 - 34

D-3

Change the Fuel Lines .................................................................................. 4 - 35

D-4

Check Engine Valve Clearance - Gasoline/LPG Models .............................. 4 - 36

D-5

Check Engine Cylinder Compression - Gasoline/LPG Models ..................... 4 - 36

D-6

Clean PCV Hoses, Tubes, and Fittings - Gasoline/LPG Models .................. 4 - 37

D-7

Check the Engine Nozzle Injection Pressure - Diesel Models ...................... 4 - 38

D-8

Check Injection Timing - Diesel Models ........................................................ 4 - 38

D-9

Replace The Timing Belt - Ford .................................................................... 4 - 38

Genie Z-45/22

vii

Service Manual - First Edition

TABLE OF CONTENTS

Section Five

Troubleshooting Flow Charts

Introduction ............................................................................................................... 5 - 1

viii

Engine Will Not Crank Over ............................................................................ 5 - 3

Engine Cranks But Will Not Start - Gasoline/LPG Models .............................. 5 - 4

Engine Cranks But Will Not Start - Diesel Models .......................................... 5 - 9

Engine Choke Inoperative - Gasoline/LPG Models ....................................... 5 - 11

Engine Glow Plugs Inoperative - Diesel Models

See B-11, Check The Glow Plugs ................................................................ 4 - 15

Engine Will Not Start On LPG, But Will Start On Gasoline

- Gasoline/LPG Models ................................................................................. 5 - 13

Engine Will Not Start On Gasoline, But Will Start On LPG

- Gasoline/LPG Models ................................................................................. 5 - 14

Engine High Idle Inoperative - Gasoline/LPG Models ................................... 5 - 15

Engine Low Idle Inoperative - Gasoline/LPG Models .................................... 5 - 17

10

Engine High Idle Inoperative - Diesel Models ............................................... 5 - 18

11

Engine Low Idle Inoperative - Diesel Models ................................................ 5 - 19

12

All Functions Inoperative, Engine Starts and Runs ....................................... 5 - 20

13

All Lift and Steer Functions Inoperative, Drive Functions Operational .......... 5 - 21

14

Ground Controls Inoperative, Platform Controls Operate Normally .............. 5 - 22

15

Platform Controls Inoperative, Ground Controls Operate Normally .............. 5 - 23

16

Secondary Boom Up Function Inoperative ................................................... 5 - 24

17

Secondary Boom Down Function Inoperative ............................................... 5 - 27

18

Primary Boom Up Function Inoperative ........................................................ 5 - 29

19

Primary Boom Down Function Inoperative ................................................... 5 - 31

20

Primary Boom Extend Function Inoperative ................................................. 5 - 33

21

Primary Boom Retract Function Inoperative ................................................. 5 - 35

22

Turntable Rotate Function Inoperative .......................................................... 5 - 36

23

Turntable Rotate Left Function Inoperative................................................... 5 - 38

24

Turntable Rotate Right Function Inoperative ................................................ 5 - 39

25

All Platform Leveling Functions Inoperative .................................................. 5 - 40

26

Platform Level Up Function Inoperative ........................................................ 5 - 41

27

Platform Level Down Function Inoperative ................................................... 5 - 42

Genie Z-45/22

Part No. 29487

Service Manual - First Edition

TABLE OF CONTENTS

Section Five

Section Six

Troubleshooting Flow Charts, continued

28

Platform Rotate Left Function Inoperative .................................................... 5 - 43

29

Platform Rotate Right Function Inoperative .................................................. 5 - 44

30

Oscillate Lock-out Function Inoperative ........................................................ 5 - 45

31

Steer Left Function Inoperative ..................................................................... 5 - 46

32

Steer Right Function Inoperative .................................................................. 5 - 47

33

All Drive Functions Inoperative, All Other Functions Operate Normally ........ 5 - 48

34

Drive Forward Or Reverse Function Inoperative .......................................... 5 - 50

35

High Range Drive Function Inoperative ........................................................ 5 - 51

36

Low Range Drive Function Inoperative ......................................................... 5 - 53

37

Machine Will Not Drive At Full Speed ........................................................... 5 - 54

38

Machine Drives At Full Speed With Platform Elevated ................................. 5 - 55

39

Drive Enable System Is Malfunctioning ........................................................ 5 - 56

40

Auxiliary Functions Inoperative ..................................................................... 5 - 57

Schematics
Introduction ................................................................................................................. 6-1
Electrical Symbol Legend ........................................................................................... 6-2
Electrical Schematic - Gasoline/LPG Models ............................................................. 6-3
Ground Control Box Legend - Gasoline/LPG Models ................................................. 6-5
Relay Panel Legend - Gasoline/LPG Models ............................................................. 6-6
Platform Control Box Legend - Gasoline/LPG Models ............................................... 6-7
Electrical Schematic - Diesel Models ......................................................................... 6-8
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

ix

Service Manual - First Edition

TABLE OF CONTENTS

Section Seven

Repair Procedures
Introduction ............................................................................................................... 7 - 1
Platform Controls
1-1

Joystick Controllers ......................................................................................... 7 - 2

1-2

Horsepower Limiter Board .............................................................................. 7 - 6

1-3

Foot Switch ..................................................................................................... 7 - 8

1-4

Resistors ......................................................................................................... 7 - 8

1-5

Toggle Switches ............................................................................................. 7 - 9

Platform Components
2-1

Platform ........................................................................................................ 7 - 10

2-2

Platform Leveling Slave Cylinder .................................................................. 7 - 10

2-3

Platform Rotator ........................................................................................... 7 - 11

Primary Boom Components

3-1

Plastic Cable Track ....................................................................................... 7 - 13

3-2

Primary Boom ............................................................................................... 7 - 13

3-3

Primary Boom Lift Cylinder ........................................................................... 7 - 16

3-4

Extension Cylinder ........................................................................................ 7 - 18

3-5

Platform Leveling Master Cylinder ................................................................ 7 - 19

Secondary Boom Components

4-1

Secondary Boom .......................................................................................... 7 - 21

4-2

Secondary Boom Lift Cylinders..................................................................... 7 - 26

Turntable Covers
5-1

Turntable Covers .......................................................................................... 7 - 27

Kubota V1702-B Engine

6-1

Timing Adjustment ........................................................................................ 7 - 28

6-2

Glow Plugs .................................................................................................... 7 - 28

6-3

RPM Adjustment ........................................................................................... 7 - 28

6-4

Flex Plate ...................................................................................................... 7 - 28

6-5

Water Temperature and Oil Pressure Switches ............................................ 7 - 28

Ford LSG 423 Engine

7-1

Governor Actuator ........................................................................................ 7 - 30

Genie Z-45/22

Part No. 29487

Service Manual - First Edition

TABLE OF CONTENTS

Section Seven

Repair Procedures, continued

7-2

Choke Adjustments ....................................................................................... 7 - 31

7-3

Timing Adjustment ........................................................................................ 7 - 32

7-4

Carburetor Adjustment .................................................................................. 7 - 32

7-5

RPM Adjustment ........................................................................................... 7 - 32

7-6

Flex Plate ...................................................................................................... 7 - 32

7-7

Water Temperature and Oil Pressure Switches ............................................ 7 - 33

7-8

Vacuum Switch ............................................................................................. 7 - 34

Ground Controls
8-1

Control Relays .............................................................................................. 7 - 35

8-2

Toggle Switches, See 1-5, Toggle Switches ................................................... 7 - 9

8-3

Wago Components ..................................................................................... 7 - 36

8-4

Resistors ....................................................................................................... 7 - 37

Relay Panel
9-1

Control Relays .............................................................................................. 7 - 38

9-2

Power Relay ................................................................................................. 7 - 39

Hydraulic Pumps
10-1 Lift/Steer Pump ............................................................................................. 7 - 40
10-2 Drive Hydraulic Pump ................................................................................... 7 - 41
Function Manifold
11-1 Function Manifold Components .................................................................... 7 - 42
11-2 Valve Adjustments ........................................................................................ 7 - 44
Fuel and Hydraulic Tanks
12-1 Hydraulic Reservoir ...................................................................................... 7 - 46
12-2 Fuel Tank ...................................................................................................... 7 - 47
Turntable Rotation Components
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

xi

Service Manual - First Edition

TABLE OF CONTENTS

Section Seven

Repair Procedures, continued

14-3 Tie Rod ......................................................................................................... 7 - 55
4WD Steering Axle Components
15-1 Yoke and Hub ............................................................................................... 7 - 56
15-2 Steering Cylinders, See 14-2, Steering Cylinders ......................................... 7 - 57
15-3 Tie Rod, See 14-3, Tie Rod .......................................................................... 7 - 55
Oscillating Axle Components
16-1 Oscillating Axle Lock-out Cylinder ................................................................ 7 - 58
Steer and Oscillate Manifold
17-1 Steer and Oscillate Manifold Components .................................................... 7 - 59
17-2 Valve Adjustments ........................................................................................ 7 - 60
Non-steering Axle Components
18-1 Drive Motor ................................................................................................... 7 - 61
18-2 Torque Hub ................................................................................................... 7 - 61
2WD Drive Manifold
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

xii

Genie Z-45/22

Part No. 29487

Service Manual - First Edition

Section 2 - Specifications

Specifications
Machine Specifications
Stowed dimension
Length
Width
Rough terrain
Industrial
Height
Weight
Ground clearance

2WD

Tires and wheels

4WD

17 ft 8 1/2 in 17 ft 10 3/4 in
5.4m
5.45m
6 ft 8 1/4 in
203.8cm
5 ft 9 5/8 in
176.8cm

6 ft 4 5/8 in
194.6cm

6 ft 6 in
1.98m

7 ft 4 in
2.23m

13860 lbs
6287kg

14410 lbs
6536kg

8 in
20.3cm

11 in
27.9cm

Length
Width

6 ft
182.8cm

6 ft
182.8cm

30 in
76.2cm

30 in
76.2cm

Operational dimensions
45 ft
13.72m

45 ft
13.72m

Maximum platform reach

23 ft
7m

23 ft
7m

21 ft 7 in
6.58m

21 ft 7 in
6.58m

1 inch
2.54cm

none

Wheelbase

6 ft 3 in
190.5cm

6 ft 3 in
190.5cm

Minimum turning radius,

outside

14 ft 4 in
4.37m

14 ft 9 in
4.49m

Minimum turning radiius,

inside

7 ft
2.13m

6 ft 8 in
2.03m

Turret rotation

359

359

Platform rotation

180

180

Maximum turret tailswing

Part No. 29487

17.5 inches

14.5 inches

Wheel width

10.5 inches

7 inches

Wheel lugs - 4WD

9 @ 5/8-18

Wheel lugs - 2WD

Front
Rear

8 @ 5/8-18
9 @ 5/8-18

8 @ 5/8-18
9 @ 5/8-18

125 ft-lbs
169.5 Nm

125 ft-lbs
169.5 Nm

14-17.5NHS

9-14.5 LT

Tread 8
Sidewall 6

59 sq in
380sq cm

43.5 sq in
280sq cm

Overall tire diameter

35.8 inches
91cm 71cm

28 inches

Tire pressure - 2WD

40 psi
2.76 bar
28 psi
1.93 bar

100 psi
6.89 bar

Tire size
Tire ply rating
Tire contact area

4WD
Fluid capacities

Maximum plaform height

Maximum up-and-over
clearance

Wheel diameter

Lug nut torque

Platform dimensions

Rough terrain Industrial

Fuel tank

15 gallons
56.8 liters

Propane tank

33.5 pounds
15.2kg

Hydraulic tank

25 gallons
95 liters

Hydraulic system
(including tank)

30 gallons
114 liters

Torque hubs

17 ounces
0.5 liters
Continuous improvement of our products is a
Genie policy. Product specifications are subject to
change without notice.

Genie Z-45/22

2-1

Section 2 - Specifications

Service Manual - First Edition

SPECIFICATIONS

Hydraulic Specifications

Performance Specifications
Drive speeds, maximum

2WD

Boom lowered, high range

5.0 mph
8.0km/h

4.8 mph
7.7km/h

Boom lowered, low range

1.1 mph
1.8km/h
or 5 feet
in 3 sec.

0.9 mph
1.4km/h
or 4 feet
in 3 sec.

Boom raised, high range

Boom raised, low range

4WD

0.68 mph / 1km/h

or 1 foot per second
0.4 mph / 0.65km/h
or 0.59 feet per second

Gradeability (stowed)

30%

Boom function speeds maximum

from platform controls

40%

Hydraulic fluid

Dexron II equivalent

Drive pump
Type

bi-directional variable
displacement piston
pump

Displacement

0 - 25 gpm
0 - 1.6 liters/second

Maximum drive
pressure

3500 psi
241.3 bar

Charge pressure

360 psi / 24.8 bar

Medium pressure filter

3 micron

Medium pressure filter

bypass pressure

50 psi / 345kPa

Boom extend

29 seconds

Drive manifold

Boom retract

25 seconds

Primary boom lift

350 psi
24.1 bar

27 seconds

Motor shift/brake
relief pressure

Primary boom lower

35 seconds

4WD front motor

flow regulators

3.0 gpm
11.4 liters/minute

Secondary boom lift

25 seconds

Secondary boom lower

25 seconds

4WD rear motor

flow regulators

4.5 gpm
17.0 liters/minute

Turntable rotate (359)

73 seconds

Platform rotate (180)

15 seconds

Platform level up

25 seconds

Platform level down

15 seconds

Multiple function
stowed to full raised

60 seconds

Multiple function
full lowered to stowed

60 seconds

2-2

Genie Z-45/22

Part No. 29487

Service Manual - First Edition

Section 2 - Specifications

SPECIFICATIONS

Front drive motors - 4WD models

Steer/oscillate manifold

Displacement per revolution 2.1 cu in / 34.4cc

Sequencing valve
pressure

1800 psi

Accumulator
pre-charge pressure

1600 psi

Rear drive motor

Displacement per revolution High - 2.8 cu in / 45.9cc
Low - 0.15 cu in / 2.5cc

Auxillary pump

Function pump
Type

fixed displacement gear

pump

Displacement

6.4 gpm @ 2150 rpm

0.4 liters/second

Function circuit return

line filter

10 micron with 25psi /

172kPa bypass

Type

fixed displacement gear

pump

Displacement

0.85 gpm
3.2 liters/minute

Auxillary pump
relief pressure

2030 psi
138 bar

Function manifold
Function relief
valve pressure

2200psi
138 bar

Secondary down relief

valve pressure

1200 psi
83 bar

Primary down relief

valve pressure

1200 psi
83 bar

Steer/oscillate
flow regulator

1.5 gpm
5.7 liters/minute

Part No. 29487

Genie Z-45/22

2-3

Section 2 - Specifications

Service Manual - First Edition

SPECIFICATIONS

Bolt Torque Specifications

Size

Threads

SAE Grade 5 Bolts

Torque - Dry
inch-pounds

10

/4

/16

/8

/16

/2

/16

/8

/4

/8

SAE Grade 8 Bolts

Torque - Dry
foot-pounds

Torque - Dry
Newton meters

Torque - Dry
inch-pounds

Torque - Dry
foot-pounds

Torque - Dry
Newton meters

24

43

60

32

49

68

20

96

11

144

16

28

120

14

168

19

18

17

23

25

34

24

19

28

25

34

16

30

41

45

61

24

35

48

50

68

14

50

68

70

95

20

55

75

80

109

13

75

102

110

149

20

90

122

120

163

12

110

149

150

204

18

120

163

170

231

11

150

204

220

298

18

170

231

240

326

10

260

353

380

515

16

300

407

420

570

430

583

600

814

14

470

637

660

895

640

868

900

1221

12

700

949

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

Service Manual - First Edition

Section 2 - Specifications

SPECIFICATIONS

Ford Engine LSG-423

Starter motor

Displacement

140 cu in / 2.3 liters

Normal engine
cranking speed

110 rpm

Number of cylinders

Current draw, normal load

150A

Bore and stroke

3.780 x 3.126 inches

96 x 79.4mm

Horsepower

63 @4000 rpm

Firing order

1-3-4-2

High engine speed

2150 rpm

Low engine speed

1200 rpm

Governing

Precision electronic

Compression pressure

psi of lowest cylinder

must be at least 75% of
highest cylinder

Valve clearances

Current draw, maximum load 460A

Current draw, no load

70A

Maximum circuit
voltage drop (normal temp)

0.5V DC

Brush length, new

0.50 inches / 12.7mm

Brush length, wear limit

0.25 inches / 6.35mm

Brush spring tension

40 ounces

Bolt torque through brush

55 - 75 inch-pounds
98 - 134gm-cm

Brush mounting
bolt torque

15 - 20 foot-pounds
2.1 - 2.7kg-m
0.005 inches / 0.127mm

Intake

0.0010 - 0.0027 inches

0.025 - 0.068mm

Maximum commutator
runout

Exhaust

0.0015 - 0.0032 inches

0.038 - 0.081mm

Battery

Lubrication System
Oil pressure (operating
temp. @ 2150 rpm)

40 - 60 psi
275.8 - 413.7kPa

Oil capacity
(including filter)

5 quarts / 4.71 liters

Type

12V, Group 24

Ampere hour

75A

Cold Cranking Ampere

875A

Reserve capacity @ 25A rate 125 minutes

Fuel Pump

Oil viscosity requirements

Below 60F / 15.5C

5W - 30

-10 to 90F / -23 to 32C

10W - 30

above -10F / -23C

10W - 40 or 10W - 50

above 25F / -4C

20W - 40 or 20W - 50

Static pressure

5.0 - 7.0 psi

Minimum volume flow

1 pint / 473cc in 25
seconds

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

Section 2 - Specifications

Service Manual - First Edition

SPECIFICATIONS

Ignition System

Cylinder head bolt / M-12

torque in sequence:
first step
second step

50 - 60
80 - 90

68 - 81
108 - 122

Distributor clamp bolt / M-10

14 - 21

19 - 28

5-8

7 - 11

Ignition spark advance

10 BTDC

Ignition coil
primary resistance

1.13 - 1.25 (75F)

Ignition coil
secondary resistance

7700 - 9300 (75F)

Distributor vacuum tube

to manifold adaptor

Type

Motorcraft AWSF-52

Gap

0.042 - 0.046 inches

1.07 - 1.18mm

Exhaust manifold to cylinder head bolt or nut / M-10

torque in sequence:
14 - 19
19 - 26
first step
20 - 30
27 - 41
second step

Coolant capacity

11.5 quarts/10.9 liters

Alternator output

35A, 14.5V

Fan belt tension

new

120 - 150 foot-pounds

used

90 - 120 foot-pounds

Flywheel to crankshaft bolt / M-10 56 - 64

76 - 87

Fuel pump to cylinder block / M-8 14 - 21

19 - 28

14 - 21

19 - 28

8 - 18

11 - 24

15 - 25

20 - 34

10 - 13.5

14 - 18

20 - 35

27 - 47

Intake manifold to cylinder

head bolt or nut / M-8
Oil pressure sending
unit to block

Bolt torque specifications

Item / Size

Oil pan drain plug to pan / M-14

Torque

Torque

(ft-lbs)

(Nm)

28 - 40

38 - 54

6-9

8 - 12

Rocker arm cover to

cylinder head / M-6

5-8

7 - 11

Belt tensioner (timing)

pivot bolt / M-10

28 - 40

38 - 54

Spark plug to cylinder

head / M-14

5 - 10

7 - 14

Belt tensioner (timing)

adjusting bolt / M-8

14 - 21

19 - 28

Temperature sending
unit to block / M-14

8 - 18

11 - 24

Camshaft gear bolt / M-12

50 - 71

68 - 96

Water jacket drain plug

to block

23 - 28

31 - 38

Camshaft thrust plate bolt / M-6

6-9

8 - 12
Water pump to block bolt

14 - 21

19 - 28

Carburetor to spacer stud / M-8

7.5 - 15

10 - 20
6-9

8 - 12

Carburetor spacer to
manifold bolt / M-8

10 - 14

14 - 19
14 - 21

19 - 28

6-9

8 - 12

Inner timing belt cover stud / M-8 14 - 21

19 - 28

Auxiliary shaft gear bolt / M-10

Auxiliary shaft thrust
plate bolt / M-6

Oil pan to block / M-6

Oil filter insert to block

Auxiliary shaft cover bolt / M-6

Crankshaft damper bolt / M-14 103 - 133

Water outlet connection

bolt / M-8
140 - 180
Cylinder front cover bolt / M-6

Outer timing belt cover bolt / M-6

2-6

Genie Z-45/22

6-9

8 - 12

Part No. 29487

Service Manual - First Edition

Section 2 - Specifications

SPECIFICATIONS

Kubota Engine V1702-B

Thermostat

Displacement

105.7 cu in / 1.732 liters

Number of cylinders

Bore and stroke

3.23 x 3.23 inches

82 x 82mm

Beginning opening

176.9 - 182.3F
80.5 - 83.5C

Full-open

203F / 95C

Starter motor

Horsepower

36 @2800 rpm

Firing order

1-3-4-2

Compression ratio

22:1

Compression pressure

427 - 469 psi

29.4 - 32.3 bar

Battery

High engine speed

2150 rpm

Low engine speed

1200 rpm

Governing

centrifugal ball
mechanical

Valve clearance, cold

0.0071 - 0.0087 inches

0.18 - 0.22mm

9.5 quarts / 9 liters

Oil viscocity
requirements

10W - 30

Brush length, new

0.7480 in. / 19mm

Brush length, minimum

0.5 in. / 12.7mm

Type

12V, Group 24

Ampere hour

75A

Cold cranking ampere

875A

Glow plug resistance

1.5

Fan belt tension

0.275-0.354 in / 7 - 9mm

Bolt torque specifications

42.7 - 64 psi
294.2 - 441.3kPa

Oil capacity
including filter

90A

Reserve capacity @ 25A rate 125 minutes

Lubrication System
Oil pressure

Current draw, no load

Item

Torque

Torque

(ft-lbs)

(Nm)

Cylinder head bolt

65 - 68

88 - 93

Fuel injector nozzle holder

to cylinder head

22 - 36

29 - 49

Engine oil should be MIL-L-2104C or have properties of

API classification CC/CD/CE grades.

Fuel injector retaining nut

to nozzle holder body

43 - 58

59 - 78

Injection System

Flywheel to crankshaft bolt

72 - 79

98 - 108

8 - 18

11 - 24

15 - 25

20 - 34

5-7

7-9

17 - 24

24 - 27

8 - 18

11 - 24

Oil pressure sending

unit to block

Injection pump

Bosch K Type

Injection pump pressure

1991 psi / 1437 bar

Injection timing

25 BTDC

Fuel requirement

Diesel number 2-D

Rocker arm cover to

cylinder head

Coolant capacity

7.25 quarts / 6.9 liters

Rocker arm mounting nuts

Alternator output

35A, 14V

Temperature sending
unit to block

Oil pan drain plug to pan

Part No. 29487

Genie Z-45/22

2-7

Section 2 - Specifications

Service Manual - First Edition

SPECIFICATIONS

Bolt torque specifications - continued

Size - Standard

ft-lbs

Nm

M-6

5-7

8-9

M-8

13 - 15

18 - 20

M-10

29 - 33

39 - 45

M-12

46 - 53

63 - 72

M-14

79 - 92

108 - 125

M-16

123 - 141

167 - 191

M-18

180 - 210

245 - 284

M-20

246 - 289

334 - 392

M-6

7-8

10 - 11

M-8

17 - 20

24 - 27

M-10

35 - 41

48 - 56

M-12

57 - 66

78 - 90

M-14

91 - 108

124 - 147

M-16

145 - 166

196 - 225

M-18

203 - 235

275 - 318

M-20

271 - 318

368 - 431

M-6

9 - 10

12 - 14

M-8

22 - 25

30 - 34

M-10

45 - 52

61 - 70

M-12

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

Size - Grade 7

Size - Grade 9

2-8

Genie Z-45/22

Part No. 29487

Service Manual - First Edition

Section 3 - Scheduled Maintenance Inspections

About This Section

Tools are
required

New parts
required

Warm engine
required

Cold engine
required

Dealer Service
recommended

Scheduled Maintenance Inspections

There are two components to this section,
maintenance tables and an inspection reporting
form.
Maintenance Tables

Observe and Obey:

Maintenance inspections shall be completed by
a person trained and qualified on the
maintenance of this machine.
Scheduled maintenance inspections shall be
completed daily, frequently (every 3 months),
annually and every 2 years as specified on the
maintenance inspection report.
Failure to properly complete each
inspection when required may
result in death, serious injury or
substantial machine damage.
Immediately tag and remove from service a
damaged or malfunctioning machine.
Repair any machine damage or malfunction
before operating machine.

The maintenance tables provide summary

information on the specific physical requirements
for each inspection.
Complete step-by-step instructions for each
scheduled maintenance procedure is provided in
section 4, Scheduled Maintenance Details.
Maintenance Inspection Report
The maintenance inspection report contains
checklists for each type of scheduled inspection.
Daily inspection
Use checklist A
Frequent inspection (every 150 hours
or three months)
Use checklists A and B
Annual inspection
Use checklists A, B and C

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

Section 3 - Scheduled Maintenance Inspections

Service Manual - First Edition

Tools are
required

New parts
required

Warm engine
required

Cold engine
required

Dealer Service
recommended

Maintenance Tables

Table A
A-1

Inspect the Operating Instruction and Safety Manuals

A-2

Inspect the Decals and Placards

A-3

Inspect for Damage, Loose or Missing Parts

A-4

Check the Engine Oil Level

A-5

Check the Engine Coolant Level

A-6

Check for Fuel Leaks

A-7

Check the Hydraulic Oil Level

A-8

Check for Hydraulic Leaks

A-9

Check Tire Pressure

A-10 Test the Platform and Ground Controls

A-11 Test Auxiliary Power Operation
A-12 Test the Tilt Level Sensor
A-13 Test the Limit Switches
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

Service Manual - First Edition

Section 3 - Scheduled Maintenance Inspections

Tools are
required

New parts
required

Warm engine
required

Cold engine
required

Dealer Service
recommended

MAINTENANCE TABLES

Table B
B-1

Check the Engine Fan Belts

B-2

Check the Radiator

B-3

Check the Exhaust System

B-4

Check the Battery

B-5

Check the Hydraulic Reservoir Filter Condition Indicator

B-6

Inspect Electrical Wiring

B-7

Inspect the Tires and Wheels

including lug nut torque

B-8

Confirm Proper Brake Configuration

B-9

Check the Oil Level in the Torque Hubs

B-10 Check the Engine Choke - Gasoline/LPG Models

B-11 Check the Glow Plugs - Diesel Models
B-12 Check and Adjust the Engine Idle Mixture
- Gasoline/LPG Models
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

Section 3 - Scheduled Maintenance Inspections

Service Manual - First Edition

Tools are
required

New parts
required

Warm engine
required

Cold engine
required

Dealer Service
recommended

MAINTENANCE TABLES

Table B, continued
B-18 Test Platform Self-leveling
B-19 Test the Service Horn
B-20 Test the Foot Switch
B-21 Test the Engine Speed Select
B-22 Test Fuel Select Operation - Gasoline/LPG Models
B-23 Test the Turntable Rotation Stop
B-24 Test the Drive Enable System
B-25 Test the Drive Brakes
B-26 Test Drive Speed - Stowed Position
B-27 Test the Alarm Package (optional equipment)
travel alarm, descent alarm, flashing beacon

Table C
C-1 Check the Primary Boom Wear Pads
C-2 Check the Turntable Rotation Bearing Bolts
C-3 Check the Free-wheel Feature
C-4

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

Service Manual - First Edition

Section 3 - Scheduled Maintenance Inspections

Tools are
required

New parts
required

Warm engine
required

Cold engine
required

Dealer Service
recommended

MAINTENANCE TABLES

Table C, continued
C-7 Replace the Drive Loop Hydraulic Filter
C-8 Replace the Diesel Fuel Filter
C-9 Replace the Gasoline Fuel Filter
C-10 Replace the PCV Valve - Gasoline/LPG Models
C-11 Clean or Replace the Distributor Cap and Rotor
- Gasoline/LPG Models
C-12 Replace the Spark Plugs - Gasoline/LPG Models
C-13 Check and Adjust the Air/Propane Mixture - Gasoline/LPG Models
C-14 Check and Adjust the Ignition Timing - Gasoline/LPG Models

Table D
D-1 Change the Hydraulic Oil
includes cleaning the suction strainers

D-2 Change or Recondition the Engine Coolant

including all coolant hoses and clamps

D-3 Change the Fuel Lines

D-4 Check Engine Valve Clearance - Gasoline/LPG Models
D-5 Check Engine Cylinder Compression - Gasoline/LPG Models
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

Section 3 - Scheduled Maintenance Inspections

Service Manual - First Edition

Tools are
required

Checklist A
New parts
required

Serial number

Warm engine
required

Model

Cold engine
required

Dealer Service
recommended

Maintenance Inspection Report

Date
Hour meter
Machine owner
Inspected by (print)

Y N R

Refer to Table A

B-19 Service horn

A-1 Operation and

Safety manuals

B-20 Foot switch

A-2 Decals and placards

B-22 Fuel select-gasoline

A-3 Damage, loose or

missing parts

B-23 Turntable rotation stop

B-21 Engine speed select

B-24 Drive enable system

A-4 Engine oil

B-25 Drive brakes

A-5 Engine coolant

B-26 Drive speed

A-6 Fuel leaks

Inspector signature
Inspector title

B-27 Alarm package

A-7 Hydraulic oil

A-8 Hydraulic leaks

Checklist C

A-9 Tire pressure

Inspector company
Instructions
Make copies of this page to use for
each inspection.
Select the appropriate checklist(s) for
the type of inspection to be performed.
Daily Inspection: A
Frequent Inspection: A+B
Annual Inspection: A+B+C
2 Year Inspection: A+B+C+D
Place a check in the appropriate box
after each inspection procedure is
completed.
Use the maintenance tables in this
section and the step-by-step
procedures in section 4 to learn how to
perform these inspections.

B-18 Platform leveling

Y N R

Refer to Table C

A-10 Platform and

ground controls

C-1 Wear pads

A-11 Auxiliary power

C-2 Turntable bolts

A-12 Tilt alarm

C-3 Free-wheel configuration

A-13 Limit switches

C-4 Worm drive gear

Perform every 100 hours:

A-14 Change engine oil
and filter

C-5 Drive torque hubs

A-15 Change engine air filter

C-8 Fuel filter-diesel

A-16 Drain fuel filter/water

separator-diesel

C-9 Fuel filter-gasoline

Checklist B
Refer to Table B
B-1 Fan belts

C-6 Hydraulic reservoir filter

C-7 Drive loop hydraulic filter

C-10 PCV valve-gasoline

Y N R

C-11 Distibutor cap-gasoline

C-12 Spark plugs
C-13 Propane adjustments
C-14 Ignition timing-gasoline

B-2 Engine radiator

B-3 Exhaust system

Checklist D

If any inspection receives an N,

remove the machine from use , repair
and re-inspect it. After repair, place a
check in the R box.

B-4 Battery

Refer to Table D

B-5 Hydraulic reservoir filter

D-1 Hydraulic oil

B-6 Electrical wiring

Legend
Y = yes, acceptable
N = no, unacceptable

B-7 Tires and wheels

D-2 Engine coolant,

hoses and clamps

B-8 Brake configuration

D-3 Fuel lines and clamps

B-9 Drive torque hubs

D-4 Engine valve clearance

-gasoline

R = repaired
Comments

B-10 Engine choke-gasoline

B-11 Glow plugs-diesel
B-12 Idle mixture-gasoline
B-13 Engine RPM

Y N R

D-5 Cylinder compression

D-6 PCV hoses and
fittings-gasoline

B-14 Key switch

D-7 Engine injection nozzle

-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

Service Manual - First Edition

Section 4 - Scheduled Maintenance Procedures

Scheduled Maintenance Procedures

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

Maintenance inspections shall be completed by

a person trained and qualified on the
maintenance of this machine.

Indicates the presence of a

hazard that will cause death or
serious injury.

Scheduled maintenance inspections shall be

completed daily, frequently (every 3 months),
annually and every 2 years as specified on the
mainentance report.

Indicates the presence of a

hazard that may cause death or
serious injury.
Indicates the presence of a
hazard that will or may cause
serious injury or damage to the
machine.

Failure to properly complete each

inspection when required may
result in death, serious injury or
substantial machine damage.
Immediately tag and remove from service a
damaged or malfunctioning machine.
Repair any machine damage or malfunction
before operating machine.

Indicates special operation or

maintenance information.
Indicates that a specific result is expected after
performing a series of steps.

Keep records on all inspections for three years.

Part No. 29487

Genie Z-45/22

4-1

Service Manual - First Edition

Section 4 - Scheduled Maintenance Procedures

Table A Procedures
A-1
Inspect the Operating Instruction
and Safety Manuals
Maintaining the Operating Instruction and Safety
manuals in good condition is essential to safe
machine operation. Manuals are included with
each machine and should be stored in the box
provided in the platform. An illegible or missing
manual will not provide safety and operational
information necessary for a safe operating
condition.
1 Check to make sure that the Operating
Instruction and Safety manuals are present in
the storage box in the platform.
2 Examine the pages of each manual to be sure
that they are legible and in good condition.
3 Always return the manuals to the storage box
after use.
Contact your Genie distributor or
Genie Industries if replacement
manuals are needed.

2 Inspect all decals for damage or illegibility.

Replace any illegible decal immediately.
Contact your Genie distributor or
Genie Industries if replacement
decals are needed.

A-3
Inspect for Damage, Loose or
Missing Parts
Daily machine condition inspections are essential
to safe machine operation and good machine
performance. Failure to locate and repair damage,
and discover loose or missing parts may result in
an unsafe operating condition.
1 Inspect the entire machine for damage and
improperly installed or missing parts including:
electrical components, wiring and electrical
cables
hydraulic hoses, fittings, cylinders and
manifolds
fuel tanks

A-2
Inspect the
Decals and Placards

drive and swing motors and gear boxes

Maintaining all of the safety and instructional

decals and placards in good condition is
mandatory for safe machine operation. Decals
alert operators and ground personnel to the many
possible hazards associated with using this
machine. They also provide users with operation
and maintenance information. An illegible decal
will fail to alert personnel of a procedure or hazard
and could result in unsafe operating conditions.

engine and related components

boom components and wear pads

tires and wheels

limit switches, alarms, horns and beacon

nuts, bolts and other fasteners
cracks in welds or structural components

1 Refer to the Decals section in the Operating

Instructions and use the decal list and
illustrations to determine that all decals and
placards are in place.

4-2

Genie Z-45/22

Part No. 29487

Service Manual - First Edition

Section 4 - Scheduled Maintenance Procedures

TABLE A

1 Check the fluid level in the coolant recovery

tank. Add water as needed.

A-4
Check the Engine Oil Level
Maintaining proper engine oil level is essential to
good engine performance and service life.
Operating the machine at an improper oil level can
damage engine components.
Check the oil level with the engine
off.
1 Check the oil level dipstick. Add oil as needed.
Specifications

Result: The fluid level should be in the normal

range.

A-6
Check for Fuel Leaks
Failure to detect and correct fuel leaks will result in
an unsafe condition. An explosion or fuel fire may
cause death or serious injury.
Engine fuels are combustible.
Inspect the machine in an open,
well-ventilated area away from
heaters, sparks, flames and
lighted tobacco. Always have an
approved fire extinguisher within
easy reach.

Ford Engine LSG 423 Lubrication System

Oil capacity

5 quarts / 4.7 liters

Oil viscosity requirements

below 60F / 15.5C

5W-30

-10 to 90F / -23 to 32C

10W-30

above -10F / -23C

10W-40 or 10W-50

above 25F / -4C

20w-40 or 20W-50

Kubota Engine V1702-B Lubrication System

Oil capacity

9.5 quarts / 9 liters

Oil viscosity
requirements

10W-30

PROCEDURES

1 Open the shutoff valve on the liquid propane

gas (LPG) tank by turning it counterclockwise.
2 Perform a visual inspection around the
following areas. An LPG detector may be
necessary to locate propane leaks.
Gasoline/LPG models:
LPG tank, hoses and fittings, solenoid shutoff
valve, LPG regulator, and carburetor

Engine oil should be MIL-L-2104C or have the

properties of AI classification CC/CD/CE grades.

gasoline tank, shutoff valve, solenoid shutoff

valve, hoses and fittings, fuel pump and
carburetor
Diesel models:

A-5
Check the Engine Coolant Level
Maintaining engine coolant at the proper level is
essential to engine life. Improper coolant level will
affect the engines cooling capability and damage
engine components. Daily checks will allow the
inspector to identify dramatic changes in coolant
level that might indicate cooling system problems.

Part No. 29487

diesel tank, shutoff valve, solenoid shutoff

valve, hoses and fittings, fuel pump, fuel filter/
water separator, fuel injection pump, fuel
injectors

Genie Z-45/22

If a fuel leak is discovered, keep

any additional personnel from
entering the area and do not
operate the machine. Repair the
leak immediately.

4-3

Service Manual - First Edition

Section 4 - Scheduled Maintenance Procedures

TABLE A

PROCEDURES

A-7
Check the Hydraulic Oil Level

all cylinders

Maintaining hydraulic oil at the proper level is

essential to machine operation. Improper hydraulic
oil levels can damage hydraulic components. Daily
checks allow the inspector to identify changes in
oil level that might indicate the presence of
hydraulic system problems.

elevate and primary booms

all valve manifolds

1 Be sure that the machine is in the fully stowed

position, then visually inspect the sight gauge
located on the side of the hydraulic oil
reservoir.

the underside of the chassis

ground area under the machine

A-9
Check Tire Pressure
This procedure does not need to
be performed on machines
equipped with the foam-filled tire
option.

Result: The hydraulic oil level should be within

the top 2 inches (5cm) of the sight gauge.
Specifications
Hydraulic oil type

Dexron II equivalent

Reservoir capacity

25 gallons / 95 liters
Do not overfill

To safeguard maximum stability, achieve optimum

machine handling and minimize tire wear, it is
essential to maintain proper pressure in all airfilled tires.
1 Check each tire with an air pressure gauge and
add air as needed.
Specifications

A-8
Check for Hydraulic Leaks

2WD model

Detecting hydraulic fluid leaks is essential to

operational safety and good machine
performance. Undiscovered leaks can develop into
hazardous situations, impair machine functions
and damage machine components.
1 Inspect for hydraulic oil puddles, dripping or
residue on or around the following areas:

industrial tire

9-14.5LT
100 psi / 6.89 bar

rough terrain tire

14-17.5NHS
40 psi / 2.76 bar

4WD model
rough terrain tire

14-17.5NHS
28 psi / 1.93 bar

hydraulic reservoirfittings, hoses and

turntable surface
engine compartmentfittings, hoses, auxiliary
power unit, main pump and turntable surface

4-4

Genie Z-45/22

Part No. 29487

Service Manual - First Edition

Section 4 - Scheduled Maintenance Procedures

TABLE A

A-10
Test the Platform and
Ground Controls

PROCEDURES

A-11
Test Auxiliary Power Operation

Testing machine functions and the Emergency

Stop buttons for malfunctions is essential for safe
machine operation. An unsafe working condition
exists if any function fails to operate properly or
either Emergency Stop button fails to stop all the
machine functions and shut off the engine. Each
function should activate, operate smoothly and be
free of hesitation, jerking and unusual noise.

Detection of auxiliary power system malfunctions

is essential for safe machine operation. An unsafe
working condition exists if the auxiliary powered
functions do not operate in the event of a main
power loss. Auxiliary power is designed for short
term emergency use only, and excessive use will
result in battery drain and pump damage.
Oscillating axle equipped
machines only: From the stowed
position, auxiliary power can not
raise the boom above the drive
limit switch. Auxiliary power can
raise the boom if it is already
raised above the drive limit switch.

1 Start the engine from the ground controls, and

then operate each machine function through a
full cycle.
Result: All machine functions should activate
and operate smoothly.
2 Push in the Emergency Stop button to the off
position.
Result: No function should operate, the engine
should stop.
Diesel models: All functions
should stop immediately. The
engine will shut off after 2 or 3
seconds.
3 Start the engine from the platform controls, and
then operate each machine function through a
full cycle.

1 Turn the key switch to ground control and pull

out the ground control Emergency Stop button
to the on position.
2 Simultaneously hold the auxiliary power switch
on while activating the following functions
through a partial cycle:
primary boom up/down
extend and retract
elevate up/down
turntable rotate right/left

Result: All machine functions should activate

and operate smoothly.
4 Push in the Emergency Stop button to the off
position.
Result: No function should operate, the engine
should stop.
As a safety feature, selecting and
operating the ground controls can
override the platform controls,
including the Emergency Stop
button.

Part No. 29487

Result: Each function should operate smoothly.

3 Turn the key switch to platform control.
4 At the platform controls, pull out the
Emergency Stop button to the on position,
press down the foot switch and repeat step 2.

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Section 4 - Scheduled Maintenance Procedures

TABLE A

PROCEDURES

A-12
Test the Tilt Level Sensor

broken or missing rollers or arms

The tilt sensor sounds an alarm in the platform

when the incline of the chassis exceeds 3.

loose wiring

missing fasteners

Select a level test area.

2 Start the engine from the ground controls.

3 Raise the primary boom above the drive limit
switch and turn the machine off.

1 Start the engine from

the platform controls.

4 Manually activate the drive limit switch.

2 Open the engine side

cover and press
down on one side of
the tilt sensor.
Result: After a 1
second delay, the
alarm in the platform
should sound.

a
a

drive limit switch

Result: The drive limit switch arm should move

freely and spring return to center. A distinct
click should be felt and heard.

A-13
Test the Limit Switches
Detecting limit switch malfunctions is essential to
safe machine operation. The drive enable limit
switch activates a signal light to inform the
operator that the platform is over the steering
wheels, and stops drive movement unless the
drive enable override switch is used. The drive
limit switch is used to restrict drive speed when
the boom is raised and signal the oscillate cylinder
to extend the lock-out wedges (oscillating axle
equipped machines). Also, on oscillating axle
equipped machines, there are two limit switches to
stop the boom from being raised unless the lock
out wedges are extended. Improperly functioning
limit switches will allow the boom to raise and/or
drive into an unsafe position.

5 Restart the engine and lower the boom into the

fully stowed position.
6 Move the key switch to platform control, and
then start the engine from the platform
controls.
7 Slowly move the drive control handle off center.
Result: The machine should move at normal
drive speeds.
8 Raise the primary boom above the drive limit
switch.
9 Slowly move the drive control handle off center.
Result: The machine should move at a reduced
drive speed.

Drive Limit Switch

1 With the engine off and the machine in the
stowed position, visually inspect the drive limit
switch for the following:

Specifications
Elevated position
2WD and 4WD

4-6

Genie Z-45/22

1 foot / 0.3 meter per

second

Part No. 29487

Service Manual - First Edition

Section 4 - Scheduled Maintenance Procedures

TABLE A

PROCEDURES

Drive Enable Limit Switch

Oscillating Axle Limit Switches

1 With the engine off and the machine in the

stowed position, visually inspect the drive
enable limit switch for the following:

1 With the engine off and the machine in the

stowed position, visually inspect the oscillate
lock-out switch for the following:

broken or missing rollers or arms

missing fasteners
loose wiring

2 Manually activate the drive enable limit switch.

b

Oscillating axle limit switch

a
limit switch
b
oscillate lock out wedge
a

broken or missing rollers or arms

missing fasteners

loose wiring

drive enable limit switch

Result: The drive enable limit switch roller

should move freely and spring return to center.
A distinct click should be felt and heard.

2 Start the engine from the ground controls and

raise the boom above the drive speed limit
switch.

3 Start the engine from the platform controls and

then swing the turntable to the left until the
platform is positioned over the left steer wheel.

Result: The oscillation cylinder should extend

the lock-out wedges. The boom should stop
moving until the wedges are fully extended.

Result: The platform over steer wheels

indicator light should be on. Drive movement
should stop until the drive enable override
switch is activated.
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.

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TABLE A

PROCEDURES

A-14
Replace the Engine Oil and Filter
Engine specifications require that
this procedure be performed every
100 hours. Perform this procedure
more often if dusty conditions
exist or the machine is subjected
to extended low idle operation.
Periodic replacement of the engine oil and filter is
essential to good engine performance. Operating
the machine with an improper oil level or
neglecting periodic oil and filter changes can
damage engine components. A daily check of
elapsed machine hours against the hours noted on
the oil filter will allow the inspector to anticipate
and perform oil and filter changes at the 100 hour
interval.
Perform this procedure after
warming the engine to normal
operating temperature.
Beware of hot engine parts and
oil. Contact with hot engine oil
and/or engine parts may cause
severe burns.
1 Remove the oil filler cap located on the valve
cover.
2 Pull the end of the oil drain hose out from under
the engine.

b
a
b

4-8

3 Remove the plug from the end of the drain

hose and allow all of the oil from the engine to
drain into a container capable of holding 3
gallons.
4 Re-install the plug into the drain hose.
5 Use an oil filter wrench and remove the filter.
Ford models: Remove the 3 bolts from the
engine pivot plate. Swing the engine pivot plate
away from the machine to access the oil filter.
6 Apply a thin layer of oil to the new oil filter
gasket. Then install the filter and tighten it
securely by hand.
7 Fill the engine with new oil per specifications
and replace the filler cap.
8 Start the engine from the ground controls.
Allow the engine to run for 30 seconds and
then turn the engine off.
9 Check the oil filter and the oil drain hose for
leaks.
10 Use an indelible ink marker to write the date
and number of hours from the hour meter on
the oil filter.
Ford Models: Swing the engine pivoy plate
back to its original position and replace the
three retaining bolts.
11 Check the engine oil level dipstick. Add oil if
needed.

pivot plate bolts

oil drain hose

Genie Z-45/22

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Section 4 - Scheduled Maintenance Procedures

TABLE A

A-15
Change the Engine Air Filter

Specifications
Ford Engine LSG 423 Lubrication System
Oil capacity

Engine specifications require that

this procedure be performed every
100 hours. Perform this procedure
more often if dusty conditions
exist.

5 quarts / 4.7 liters

Oil viscosity requirements

below 60F / 15.5C

5W-30

-10 to 90F / -23 to 32C

10W-30

above -10F / -23C

10W-40 or 10W-50

above 25F / -4C

20W-40 or 20W-50

Maintaining the engine air filter in good condition is

essential to good engine performance and service
life. Failure to perform this procedure can lead to
poor engine performance and component damage.

Kubota Engine V1702-B Lubrication System

Oil capacity

9.5 quarts / 9 liters

Oil viscosity
requirements

10W-30

PROCEDURES

Perform this procedure with the

engine off.
1 Remove the end cap from the air cleaner
canister.
Kubota models: Remove the air
cleaner canister mounting straps
then the end cap.

Engine oil should be MIL-L-2104C or have the

properties of AI classification CC/CD/CE grades.

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.

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TABLE A

PROCEDURES

1 Loosen the vent plug located on the fuel filter/

water separator head.

A-16
Drain the Fuel Filter/ Water
Separator - Diesel Models
Engine specifications require that
this procedure be performed every
100 hours, along with an oil and
filter change. Poor fuel quality or
very wet conditions may
necessitate performing this
procedure more often.

2 Loosen the drain plug located at the bottom of

the bowl. Allow the water to drain into a
container until fuel starts to come out.
Immediately tighten the drain plug.
3 Tighten the vent plug and clean up any spills or
wet surfaces.
If the fuel bowl is completely
drained, you must prime the fuel
filter/water separator before
starting the engine. Refer to C-8
in this section, Replace The
Diesel Fuel Filter, for instructions
on how to prime the fuel filter/
water separator.

Proper maintenance of the fuel filter/water

separator is essential for good engine
performance. Failure to perform this procedure
can lead to poor engine performance and
component damage.
Perform this procedure with the
engine off.

4 Start the engine from the ground controls and

check the fuel filter/water separator for leaks.

Engine fuels are explosive.

Perform this procedure in an
open, well-ventilated area away
from heaters, sparks, flames and
lighted tobacco. Always have an
approved fire extinguisher within
easy reach.
a

e
d

b
c

Fuel filter/water seperator

a
b
c
d
e

4 - 10

head bolt
filter bowl
drain plug
vent plug
separator head

Genie Z-45/22

Part No. 29487

Service Manual - First Edition

Section 4 - Scheduled Maintenance Procedures

Table B Procedures
check allows the inspector to identify changes in
the condition of the radiator that might indicate
cooling system problems.

B-1
Check the Engine Fan Belts
Maintaining the engine fan belts is essential to
good engine performance and service life. The
machine will not operate properly with a loose or
defective belt and continued use may cause
component damage.
Do not inspect while the engine is
running. Remove the key to
secure from operation.
Beware of hot engine
components. Contact with hot
engine components may cause
severe burns.
1 Inspect the engine
fan belts for:

Do not inspect while the engine is

running. Remove the key to
secure from operation.
Beware of hot engine
components. Contact with hot
engine components may cause
severe burns.
1 Inspect the radiator for leaks and physical
damage.
2 Clean the radiator fins of debris and foreign
materials.

B-3
Check the Exhaust System

cracking
glazing

Maintaining the exhaust system is essential to

good engine performance and service life.
Operating the machine with a damaged or leaking
exhaust system can cause component damage
and unsafe operating conditions.

separation
breaks

Do not inspect while the engine is

running. Remove the key to
secure from operation.

2 Check the engine fan belts for proper tension.

Beware of hot engine

components. Contact with hot
engine components may cause
severe burns.

Specifications
Belt Deflection

3/8 inch - 1/2 inch

0.9cm - 1.2cm

1 Be sure that all nuts and bolts are tight.

2 Inspect all welds for cracks.
3 Inspect for exhaust leaks; i.e., carbon buildup
around seams and joints.

B-2
Check the Radiator
Maintaining the radiator in good condition is
essential for good engine performance. Operating
a machine with a damaged or leaking radiator may
result in engine damage. Also, restricting air flow
through the radiator (i.e., dirt or debris) will affect
the performance of the cooling system. A frequent
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TABLE B

PROCEDURES

B-4
Check the Battery
The factory ships each machine
with a sealed battery; checking
the water level is not necessary. If
the battery is replaced with
another type, the battery acid
level and specific gravity should
be checked at this time.
Proper battery condition is essential to good
engine performance and operational safety.
Improper fluid levels or damaged cables and
connections can result in engine component
damage and extremely hazardous conditions.

B-5
Check the Hydraulic Reservoir
Filter Condition Indicator
Maintaining the hydraulic reservoir filter in good
condition is essential to good system performance
and safe machine operation. The filter condition
indicator will show when the hydraulic flow is
bypassing a clogged filter. If the filter is not
frequently checked and replaced, impurities will
remain in the hydraulic system and cause
component damage.
1 Start the engine from the platform controls.

Batteries contain acid. Avoid

spilling or contacting battery acid.
Neutralize battery acid spills with
baking soda and water.

2 Switch the engine speed control to high idle

(rabbit symbol).
3 Inspect the filter condition indicator.
a

1 Put on protective clothing and eye wear if

batteries are to be opened.
2 Be sure that the battery cable connections are
free of corrosion.

3 Be sure that the battery hold down and cable

connections are tight.

c
a
b
c

filter condition indicator

filter
hydraulic reservoir

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

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Section 4 - Scheduled Maintenance Procedures

TABLE B

PROCEDURES

B-6
Inspect Electrical Wiring

B-7
Inspect the Tires and Wheels

Maintaining electrical wiring in good condition is

essential to safe operation and good machine
performance. Failure to find and replace burnt,
chafed, corroded or pinched wires could result in
unsafe operating conditions and may cause
component damage.

Maintaining the tires and wheels in good condition

is essential to safe operation and good
performance. Tire and/or wheel failure could result
in a machine tip-over. Component damage may
also result if problems are not discovered and
repaired in a timely fashion.

Electrocution hazard. Contact with

hot or live circuits may result in
death or serious injury. Remove
all rings, watches and other
jewelry.
1 Inspect the following areas for burnt, chafed,
corroded and loose wires:
engine compartment relay panel

1 Check all tire treads and sidewalls for cuts,

cracks, punctures and unusual wear.
2 Check each wheel for damage, bends and
cracked welds.
3 Check every lug nut for proper torque.
4 Check the pressure in each air-filled tire.
Specifications:

engine wiring harness

Tires and Wheels

Rough terrain

Wheel lugs - 4WD

9 @ 5/8-18

2 Start the engine from the ground controls, and

then raise the secondary boom until the upper
pivot is above the turntable covers.

Wheel lugs - 2WD

front
rear

8 @ 5/8-18
8 @ 5/8-18

3 Inspect the upper pivot area for burnt, chafed

and pinched cables.

Lug nut torque

4 Fully lower the boom into the stowed position

and turn the engine off.

Tire size

5 Inspect the following areas for burnt, chafed,

corroded, pinched and loose wires:

Tire ply rating

inside of the ground control box

Industrial

turntable manifold wiring

cable track on the primary and secondary

booms
primary boom to platform cable harness

Tire pressure - 2WD

9 @ 5/8-18
9 @ 5/8-18
125
ft-lbs125
169.5
Nm ft-lbs
169.5 Nm
14-17.5NHS
9 - 14.5 LT
Tread 8
Tread 8

Tire pressure - 4WD

Sidewall 6

inside of the platform control box

40 psi
100 psi
2.76 bar6.89 bar
28 psi
1.93 bar

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Section 4 - Scheduled Maintenance Procedures

TABLE B

PROCEDURES

B-8
Confirm Proper
Brake Configuration

B-9
Check the Oil Level
in the Torque Hubs

Proper brake configuration is essential to safe

operation and good machine performance.
Hydrostatic brakes and hydraulically released,
spring applied individual wheel brakes can appear
to operate normally when they are actually not
fully operational.

Failure to maintain proper torque hub oil levels

may cause the machine to perform poorly and
continued use may cause severe component
damage.

1 Check the torque hub disconnect caps to be

sure they are in the engaged position.

1 Drive the machine to rotate the hub until the

side plugs are located one on top and the other
at 90 degrees.

brake disengage position

brake engage position

2 On 4WD models, be sure the free-wheel valve

on the drive pump is closed (clockwise).
2 Remove the plug located at 90 degrees and
check the oil level.
a

b
c

a
b
c

drive pump
lift pump
free-wheel valve

Result: The oil level should be even with the

bottom of the plug hole.
3 If necessary, remove the top plug and add oil
until the oil level is even with the bottom of the
side plug hole, then re-install the plugs into the
hub.
4 Repeat this procedure for each torque hub.
Specifications
Capacity

17 fluid ounces / 0.5

liters

Type
SAE 90 multipurpose
hypoid gear oil - API
service classification GL5

4 - 14

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Section 4 - Scheduled Maintenance Procedures

TABLE B

4 Turn the key switch to platform control.

B-10
Check the Engine Choke Gasoline/LPG Models

5 Pull out the platform control Emergency Stop

button to the on position and then operate the
choke switch and listen for choke solenoid
operation.

Automatic Choke
The machine is equipped with an
automatic choke if a choke switch
can't be found near the start
switch. The automatic choke does
not need to be inspected or
adjusted unless the following
conditions exist:
The machine does not start
easily in cold temperatures.
The engine does not run
smoothly after a cold start.
See 7-4, Choke Adjustments.

B-11
Check the Glow Plugs
- Diesel Models
Maintaining the glow plugs in good condition is
essential to good engine performance and service
life. Improperly functioning glow plugs will cause
the engine to perform poorly and may result in
component damage.
Perform this procedure with the
engine turned off.

Manual Choke

1 Connect an ohmmeter between the far left

glow plug and machine ground.

A properly functioning choke is essential to good

engine performance. An improperly functioning
choke will result in difficulty with engine starting.

Result: The resistance should be approximately

0.4.

1 Check the choke linkage connections.

a
b

2 If the ohm reading is different than 0.4,

remove each wire from the four individual glow
plugs. Then, one glow plug at a time, check the
resistance between the glow plug and machine
ground.
Result: The resistance should be approximately
1.6 for each individual glow plug.

c
a
b
c
d

PROCEDURES

3 Turn the machine on, but do not start the

engine.

linkage
carburetor
linkage lock nuts
choke solenoid

4 Connect a volt meter to the number four glow

plug and machine ground.

2 Turn the key switch to ground control and then

pull out the ground control Emergency Stop
button to the on position.

5 Hold the glow plug switch in the on position.

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.

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Service Manual - First Edition

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TABLE B

PROCEDURES

B-12
Check and Adjust the Engine Idle
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

a

B-13
Check and Adjust
the Engine RPM

adjustment screw

3 Move the engine speed control switch to high

idle (rabbit symbol) from the ground controls.
Result: High idle should be 2150 rpm.

Maintaining the engine rpm at the proper setting

for both low and high idle is essential to good
engine performance and service life. The machine
will not operate properly if the rpm is incorrect and
continued use may cause component damage.
Perform this procedure in gasoline
mode with the engine at normal
operating temperature.
1 Connect an rpm gauge to the engine, and then
start the engine from the ground controls.

Adjust high idle rpm, if necessary, by

following the appropriate steps for the engine
model:
Ford engines: 4 through 7
4 Turn the engine off.
5 Remove the mounting fasteners from the
electronic governor located on the relay panel,
and then remove the back panel from the
governor.

Result: Low idle should be 1200 rpm.

Electrocution Hazard. Contact

with hot or live circuits may result
in death or serious injury. Remove
all rings, watches and other
jewelry.

Skip to step 3 if the low idle rpm is correct.

2 Turn the idle adjustment screw clockwise to
increase rpm or counterclockwise to decrease
rpm.

6 Restart the engine, turn the speed set screw

clockwise to increase rpm or counterclockwise
to decrease rpm.

a
Ford high idle adjustment

Kubota low idle adjustment

a
adjustment screw

4 - 16

Genie Z-45/22

high idle adjustment

Part No. 29487

Service Manual - First Edition

Section 4 - Scheduled Maintenance Procedures

TABLE B

7 Re-assemble the governor and recheck high

idle rpm.

PROCEDURES

B-14
Test the Key Switch

Kubota engines: 8 through 11

8 Turn the engine off.
9 Loosen the lock nut on the Trombetta solenoid,
and then pull the rubber boot off the solenoid.
a

Proper key switch action and response is essential

to safe machine operation. The machine can be
operated from the ground or platform controls and
the activation of one or the other is accomplished
with the key switch. Failure of the key switch to
activate the appropriate control panel could cause
a hazardous operating situation.
1 Pull out the Emergency Stop button to the on
position at both the ground and platform
controls.

2 Turn the key switch to ground control, start the

engine and then turn the key switch to
platform control.

Kubota high idle adjustment

a
b
c
d

3 Operate each machine function from the

ground controls.

rubber boot
adjustment nut
lock nut
yoke

Result: The machine functions should not

operate.

10 Screw the adjustment nut into the yoke to

increase the rpm. Back the adjustment nut out
of the yoke to decrease rpm.
Be sure that the stop screw on the
governor throttle lever does not
limit solenoid travel. The solenoid
must fully retract when energized
to prevent solenoid damage.
11 Reconnect the rubber boot to the solenoid.
Then tighten the lock nut and recheck the rpm.

4 Turn the key switch to ground control.

5 Operate each machine function from the
platform controls.
Result: The machine functions should not
operate.
6 Turn the key switch to the off position.
Result: The engine should stop and no
functions should operate.

Specifications
Ford and Kubota Engines
Low idle

1200 rpm

High idle

2150 rpm

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TABLE B

PROCEDURES

B-15
Test the Emergency Stop Buttons
Properly functioning Emergency Stop buttons are
essential for safe machine operation. An
improperly operating Emergency Stop button will
fail to shut off power and stop all machine
functions resulting in a hazardous situation for
ground and platform personnel.
As a safety feature, selecting and
operating the ground controls can
override the platform controls,
including the Emergency Stop
button.
1 Start the engine from the ground controls.
2 Push down the Emergency Stop button to the
off position.

ground controls whether or not the Emergency

Stop button on the platform controls is in the on or
off position. This function is particularly useful if
the operator at the platform controls can not return
the boom to the stowed position.
1 Push in the platform Emergency Stop button to
the off position.
2 Start the engine from the ground controls.
3 Operate each boom function through a partial
cycle.
Result: All boom functions should operate.

B-17
Test the Oscillate Lock-out
Perform this test on oscillating
axle equipped machines only.

Result: The engine should be off and no

machine functions should operate.
Diesel models: All functions
should stop immediately. The
engine will shut off after 2 or 3
seconds.

Proper axle oscillate lock-out when the boom is

raised is essential to safe machine operation. If
the lock-out wedges do not extend when the boom
is raised, the stability of the machine is
compromised and it may tip over.

3 Start the engine from the platform controls.

4 Push down the Emergency Stop button to the
off position.

1 From the ground controls, raise the primary

boom above the drive speed limit switch.

Result: The engine should be off and no

machine functions should operate.
The ground Emergency Stop
button will stop all machine
operation, even if the key switch is
switched to platform control.

a
b

Oscillating axle limit switch

a
limit switch
b
oscillating lock out wedge

B-16
Test the Ground Control Override
A properly functioning ground control override is
essential to safe machine operation. The ground
control override function is intended to allow
ground personnel to operate the machine from the
4 - 18

Result: The oscillate cylinder should extend the

lock-out wedges 3 inches (7.6cm) past the
chassis frame. The boom should stop moving
until the wedges are fully extended.

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Section 4 - Scheduled Maintenance Procedures

TABLE B

PROCEDURES

B-19
Test the Service Horn
a

A functional service horn is essential to safe

machine operation. The service horn is activated
at the platform controls and sounds at the ground
as a warning to ground personnel. An improperly
functioning horn will prevent the operator from
alerting ground personnel of hazards or unsafe
conditions.

3 inches

oscillate lock out wedge

2 Lower the primary boom onto its resting pad.

Result: The oscillate lock-out wedges should
fully retract.
When the primary and secondary
booms are fully lowered into the
stowed position and the engine is
turned off, the oscillate lock-out
wedges may partially extend. This
should not be mistaken for the full
lock-out position.

B-18
Test Platform Self-leveling
Precise automatic platform self-leveling throughout
the full cycle of boom raising and lowering is
essential for safe machine operation. The platform
is maintained at level by a hydraulic cylinder
(leveling slave cylinder) which is controlled by the
master cylinder located at the base of the primary
boom. A platform self-leveling failure creates an
unsafe working condition for platform and ground
personnel.
1 Start the engine from the ground controls, then
fully lower the boom into the stowed position.
2 Adjust the platform to a level position using the
manual platform leveling switch.
3 Raise and lower the primary boom through a
full cycle.
Result: The platform should remain level at all
times to within 5 degrees.
Part No. 29487

1 Turn the key switch to platform control and pull

out the Emergency Stop button to the on
position.
2 Push down the service horn button at the
platform controls.
Result: The service horn should sound.

B-20
Test the Foot Switch
A properly functioning foot switch is essential to
safe machine operation. Machine functions should
activate and operate smoothly as long as the foot
switch is pressed down, and promptly stop when
the foot switch is released. The foot switch will
also shift the engine into high idle mode if the idle
select is switched to the rabbit and foot switch
symbol. An improperly functioning foot switch can
cause an unsafe working condition and endanger
platform and ground personnel.
The engine should not start if the
foot switch is pressed down.
1 Start the engine from the platform controls.
2 Without pressing down the foot switch, operate
the machine functions.
Result: The machine functions should not
operate.
3 Press down the foot switch and operate the
machine functions.
Result: The machine functions should operate.

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TABLE B

PROCEDURES

Result: The engine should not change to high

idle.

B-21
Test the Engine Speed Select

8 Press down the foot switch.

A properly operating engine rpm select switch is
essential to good engine performance and safe
machine operation. There are three rpm settings:

Result: The engine should change to high idle.

Specifications

The foot switch activated high idle (rabbit and foot

switch symbols) should be sued for normal
machine operation. This selection activates high
idle only when the foot switch is pressed down.

High idle

2150 rpm

Low idle

1200 rpm

Low idle (turtle symbol) mode allows the operator

to control individual boom functions only.
High idle (rabbit symbol) mode allows the operator
to control multiple boom and/or drive functions
simultaneously. This setting maintains a consistent
high idle and usually selected only when the
generator option is being used.
1 Pull out the Emergency Stop button to the on
position at both the ground and platform
controls.
2 Start the engine from the ground controls. Then
move the engine speed control switch to high
idle (rabbit symbol) and hold in the on position.

B-22
Test Fuel Select Operation Gasoline/LPG Models
The ability to select and switch between gasoline
and LP fuels as needed is essential to safe
machine operation. A fuel selection can be made
when the engine is running or not. Switching
malfunctions and/or the failure of the engine to run
properly in both fuel modes and through all idle
speeds can indicate fuel system problems that
could develop into a hazardous situation.

Result: The engine should change to high idle.

Perform this test after checking

the gasoline and propane gas fuel
levels, and warming the engine to
normal operating temperature.

3 Release the engine speed control switch.

Result: The engine should return to low idle.
4 Turn the key switch to platform controls.

1 Move the fuel select switch to gasoline and

then move the engine speed control switch to
foot switch activated high idle (rabbit and foot
switch symbol).

5 At the platform controls, move the engine

speed control switch to high idle (rabbit
symbol).
Result: The engine should change to high idle.
6 Move the engine speed control switch to low
idle (turtle symbol).
Result: The engine should change to low idle.
7 Move the engine speed control switch to foot
switch activated high idle (rabbit and foot
switch symbol).

2 Start the engine from the platform controls and

allow it to run at low idle.
3 Press down the foot switch to allow the engine
to run at high idle.
Result: The engine should start promptly and
operate smoothly in low and high idle.
4 Release the foot switch and stop the engine.
5 Move the fuel select switch to propane gas.

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TABLE B

6 Restart the engine and allow it to run at low

idle.
7 Press down the foot switch to allow the engine
to run at high idle.
Result: The engine should start promptly and
operate smoothly in low and high idle.
The engine may hesitate
momentarily and then continue to
run on the selected fuel if the fuel
source is switched while the
engine is running.

B-23
Test the Turntable Rotation Stop
The turntable is capable of rotating the boom 359
degrees and is stopped midpoint between the
steering wheels by the rotation stop. Detecting a
rotation stop malfunction is essential to safe
operation and good machine performance. If the
turntable rotates past the rotation stop, component
damage may result.
1 Start the engine from the platform controls.

PROCEDURES

stopped and the indicator light turns on and the

drive enable switch must be used to reactivate the
drive function. This should inform the operator that
the machine will move in the opposite direction
that the drive and steer controls are moved. An
improperly functioning drive enable system may
allow the boom to be moved into an unsafe
position.
1 Start the engine from the platform controls.
2 Swing the turntable to the right until the
platform is positioned over the right steer
wheel.
Result: Platform over steer wheel indicator light
should turn on.
3 Slowly move drive control handle off center.
Always use the color coded
direction arrows on the platform
control panel and the drive
chassis to identify which direction
the machine will travel.
Result: Drive function should not operate.
4 Hold drive enable toggle switch to either side
and slowly move the drive control handle off
center.

2 Swing the turntable to the left as far as it will

go.
Result: Movement should stop when the boom
reaches mid-point between the steer tires.
3 Swing the turntable to the right full circle as far
as it will go.
Result: Movement should stop when the boom
reaches mid-point between the steer tires.

Result: Drive function should operate.

5 Swing the turntable to the left until platform is
positioned over the left steer tire.
Result: Platform over steer wheel indicator light
should come on.

B-24
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

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TABLE B

PROCEDURES

B-25
Test the Drive Brakes
Proper brake action is essential to safe machine
operation. The Brake function should operate
smoothly, free of hesitation, jerking and unusual
noise. Hydrostatic brakes and hydraulically
released individual wheel brakes can appear to
operate normally when not fully operational.
Be sure that the machine is not in
free-wheel or partial free-wheel
configuration. Refer to B-8 in this
section, Confirm Proper Brake
Configuration.
Select a test area that is firm,
level and free of obstructions.
1 Mark a test line on the ground for reference.
2 Start the engine from the platform controls, and
then select high drive mode (2 wheel symbol).
3 Fully lower the boom into the stowed position.
4 Choose a point on the machine; i.e., contact
patch of a rear tire, as a visual reference for
use when crossing the test line.
5 Bring the machine to top drive speed before
reaching the test line. Release the drive
joystick when your reference point on the
machine crosses the test line.
6 Measure the distance between the test line and
your machine reference point.
The brakes must be able to hold
the machine on any slope it is
able to climb.

B-26
Test Drive Speed - Stowed
Position
Proper drive function movement is essential to
safe machine operation. The drive function should
respond quickly and smoothly to operator control.
Drive performance should also be free of
hesitation, jerking and unusual noise over the
entire proportionally controlled speed range.
Select a test area that is firm,
level and free of obstructions.
1 Create start and finish lines by marking two
lines on the ground 20 feet (6m) apart.
2 Start the engine from the platform controls, and
then select high drive mode (2 wheel symbol).
3 Move the engine speed control switch to high
idle (rabbit & foot switch), and then fully lower
the boom into the stowed position.
4 Choose a point on the machine; i.e., contact
patch of a rear tire, as a visual reference for
use when crossing the start and finish lines.
5 Bring the machine to top drive speed before
reaching the start line. Begin timing when your
reference point on the machine crosses the
start line.
6 Continue at full speed and note the time when
the machine reference point passes over the
finish line.
Specifications: stowed position, high range
Distance: 20 feet / 6 meters

Specifications: high range, paved surface

4WD

Stopping distance,
normal operating temp.

2WD

4 - 22

5.5 to 6 feet /
1.67 to 1.82 meters

2.85 seconds (0.25

seconds)
2.75 seconds (0.25
seconds)

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Section 4 - Scheduled Maintenance Procedures

TABLE B

PROCEDURES

3 Turn the key switch to platform control, then

from the platform controls, pull out the
Emergency Stop button to the on position.

B-27
Test the Alarm Package
(optional equipment)

Result: The flashing beacon should be on and

flashing.

The alarm package includes:

4 Press down the foot switch. Move the primary

boom control handle to the down position, hold
for a moment and then release it. Move the
secondary boom control handle to the down
position, hold for a moment and then release it.

travel alarm
descent alarm
flashing beacon
Alarms and beacons are installed to alert
operators and ground personnel of machine
proximity and motion. The alarm package
components are installed on the right side, on top
of the turntable cover.
The alarm and beacons will
operate with the engine
running or not.
1 At the ground controls pull out the Emergency
Stop button to the on position and turn the key
switch to ground control.

Result: The descent alarm should sound when

each control handle is held down.
6 Press down the foot switch. Slowly move the
drive control handle off center, hold for a
moment and then release it. Slowly move the
drive control handle off center in the opposite
direction, hold for a moment and then
release it.
Result: The travel alarm should sound when
the drive control handle is moved off center in
either direction.

Result: The flashing beacon should be on and

flashing.
2 Move the primary boom switch to the down
position, hold for a moment and then release it.
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.

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Table C Procedures
C-1
Check the Primary Boom
Wear Pads

Maintaining the primary boom wear pads in good

condition is essential to safe machine operation.
Wear pads are placed on boom surfaces to
provide a low friction, replaceable wear pad
between moving parts. Improperly shimmed wear
pads or continued use of worn out wear pads may
result in component damage and unsafe operating
conditions.

a
b
c

1 Start the engine from the ground controls, then

raise the end of the primary boom to a
comfortable working height (chest high).

Crushing hazard. Keep hands

away from the block and all
moving parts when lowering the
secondary boom.

2 Extend the extension boom 10 inches (25cm).

3 Measure each wear pad. Replace the pad if it is
less than 0.41 inches (1cm) thick. If the pad is
more than 0.41 inches (1cm) thick, shim as
necessary to obtain zero clearance and zero
drag.

upper mid-pivot
4x4x31 inch block
counterweight

2 Raise the primary boom until the end of the

boom is approximately 7 feet (2m) off the
ground.
3 Be sure that each turntable bolt is torqued to
190 foot-pounds (258 Newton meters).

4 Extend and retract through the entire range of

motion to check for tight spots that could cause
binding.

20

22

13
7

16

Always maintain squareness

between the primary boom outer
and inner tubes.

18

24

12

11

23

17

C-2
Check the Turntable Rotation
Bearing Bolts

14

5
21

10

19

Bolt torque sequence

Maintaining proper torque on the turntable bearing

bolts is essential to safe machine operation.
Improper bolt torque could result in an unsafe
operating condition and component damage.
1 Raise the secondary boom and place a 4x4x31
inch (78cm) block between the chassis
counterweight and the upper mid-pivot.
Carefully lower the secondary boom onto the
block.
4 - 24

15

4 Remove the support block and then lower the

primary and secondary booms to the fully
stowed position.
5 Use a forklift to support the chassis
counterweight, directly below the turntable
bearing.
6 Loosen the counterwight positioning bolt, then
remove the 2 mounting bolts.

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Section 4 - Scheduled Maintenance Procedures

TABLE C PROCEDURES

7 Carefully lower and remove the counterweight.

8 Be sure that each bearing mounting bolt. is
torqued to 190 foot-pounds (258 Newton
meters).
1

10

4 Disengage the rear brakes by turning over the

torque hub disconnect caps on each rear wheel
hub.
brake disengage position

15

13

brake engage position

12

18

5 Manually rotate each rear wheel.

Result: Each rear wheel should rotate with

minimum effort.

17

11
5

8
16

6 Re-engage the brakes by turning over the hub

disconnect caps. Carefully remove the jack
stands, lower the machine and remove the
jack.

14
2

Bolt torque sequence

Collision hazard. Failure to reengage the brakes may result in

death or serious injury and
property damage.

9 Reinstall the counterweight.

C-3
Check the Free-wheel Feature

Steer wheels: 4WD models

Proper use of the free-wheel configuration is

essential to safe machine operation. The freewheel configuration is used primarily for towing. A
machine configured to free-wheel without operator
knowledge may result in death or serious injury
and property damage.
Collision hazard. Select a work
site that is firm and level.

7 Chock the drive wheels to prevent the machine

from rolling.
8 Position the lifting jack under the front axle and
center it between the steering wheels.
9 Lift the wheels off the ground and then place
jack stands under the chassis for support.
10 Open the free wheel valve, located on the drive
pump, by turning it counterclockwise two turns.

Rear drive wheels: All models

1 Chock the steer wheels to prevent the machine
from rolling.
2 Center a lifting jack of ample capacity
(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.

Part No. 29487

Genie Z-45/22

b
c

a
b
c

drive pump
lift pump
free-wheel valve

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TABLE C

PROCEDURES

11 Manually rotate each steer wheel.

Result: Each steer wheel should rotate with
minimal effort.
12 Close the free wheel valve (clockwise).
Carefully remove the jack stands, lower the
machine and remove the jack.
Collision hazard. Failure to close
the free-wheel valve may result in
death or serious injury and
property damage.

2 Raise the primary boom until the end of the

boom is approximately 7 feet (2m) off the
ground. Then shut off the engine.
3 Locate the grease fitting on the inside of the
bearing in the middle of the turntable.
4 Pump grease into the rotation bearing until you
see it coming out of the bearing seal gap.
Repeat this step with the platform in the
following locations.
platform over the drive wheels
platform over the left side
platform over the drive wheels

C-4
Grease the Turntable Rotation
Bearing and Worm Drive Gear

platform over the right side

Yearly application of lubrication to the turntable

bearing and worm drive gear is essential to good
machine performance and service life. Continued
use of an improperly greased gear will result in
component damage.

Crushing hazard. Turn the key

switch to the off position and
remove the key while pumping
grease.
5 Locate the grease fitting on the worm drive
housing.

1 Raise the secondary boom and place a 4x4x31

(78cm) block between the chassis counterweight and the upper mid-pivot. Carefully lower
the secondary boom onto the block.

a
b
b

a
b

grease fitting
grease overflow

6 Pump grease into the gear until you see it

coming out of the side of the gear housing.
Specification
a
b
c

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.

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Section 4 - Scheduled Maintenance Procedures

TABLE C PROCEDURES

C-5
Replace the Torque Hub Oil
Replacing the torque hub oil is essential for good
machine performance and service life. Failure to
replace the torque hub oil at yearly intervals may
cause the machine to perform poorly and
continued use may cause component damage.
1 Select the torque hub to be serviced. Then
drive the machine until one of the two plugs is
at the lowest point.

C-6
Replace the
Hydraulic Reservoir Filter
Replacement of the hydraulic reservoir filter is
essential for good machine performance and
service life. A dirty or clogged filter may cause the
machine to perform poorly and continued use may
cause component damage. Extremely dirty
conditions may require that the filter be replaced
more frequently.
Beware of hot oil. Contact with hot
oil may cause severe burns.

2 Remove both plugs and drain the oil.

3 Drive the machine until one plug is at the top
and the other is at 90 degrees.

Perform this procedure with the

engine off.
1 Remove the filter with an oil filter wrench.
2 Apply a thin layer of oil to the new oil filter
gasket.
3 Install the new filter and tighten it securely by
hand. Clean up any oil that may have spilled
during the installation procedure.
4 Start the engine from the ground controls.

4 Fill the hub with oil from the top hole until the oil
level is even with the bottom of the side hole.
Then re-install the plugs.

5 Inspect the filter and related components to be

sure that there are no leaks.

5 Repeat steps 1 through 4 for all the other drive

torque hubs.
Specifications
Capacity

17 fluid ounces
0.5 liters

Type

SAE 90 multipurpose
hypoid gear oil. API
classification GL5

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TABLE C

PROCEDURES

C-7
Replace the
Drive Loop Hydraulic Filter

C-8
Replace the Diesel Fuel Filter

Replacing the drive loop hydraulic filter is essential

to good machine performance and service life. A
dirty or clogged filter may cause the machine to
perform poorly and continued use may cause
component damage. Extremely dirty conditions
may require that the filter be replaced more
frequently.

Replacing the diesel fuel filter is essential to good

engine performance and service life. A dirty or
clogged filter may cause the engine to perform
poorly and continued use may cause component
damage. Extremely dirty conditions may require
that the filter be replaced more frequently.
Engine fuels are combustible.
Replace the fuel filter in an open,
well-ventilated area away from
heater, sparks, flames and lighted
tobacco. Always have an
approved fire extinguisher within
easy reach.

Beware of hot oil. Contact with hot

oil may cause severe burns.
Perform this procedure with the
engine off.
1 Rotate the filter housing counterclockwise and
remove the housing.

Perform this procedure with the

engine off.

2 Remove the filter element from the housing.

3 Inspect the housing seal and replace it if
necessary.

e
a

4 Install the new filter and hand tighten the

housing onto the filter head. Clean up any oil
that may have spilled during the installation
procedure.

5 Start the engine from the ground controls.

6 Inspect the filter assembly to ensure that there

are no leaks.
Fuel filter/water seperator
a
vent plug
b
filter bowl
c
drain plug
d
seperator head
e
head bolt

1 Loosen the vent plug located on the fuel filter/

water separator head.
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.

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TABLE C PROCEDURES

4 Remove the filter element from the bowl.

5 Apply a thin layer of oil onto the bowl gasket
and then install the new filter element.

1 Remove the 3 bolts from the engine pivot plate.

Swing the engine pivot plate away from the
machine to access the fuel filter, located near
the carburetor.

6 Tighten the drain plug and fill the bowl with

clean diesel fuel.
7 Install the bowl onto the filter head, and then
tighten the head bolt to 65 inch-pounds (7Nm).
8 Tighten the vent plug.

9 Clean up any diesel that may have spilled

during the installation procedure.

10 Start the engine from the ground controls, then

inspect the fuel filter water separator and hoses
for leaks.
If a fuel leak is discovered, keep
any additional personnel from
entering the area and do not
operate the machine. Repair the
leak immediately.

C-9
Replace the Gasoline Fuel Filter
Replacing the gasoline fuel filter is essential to
good engine performance and service life. A dirty
or clogged filter may cause the engine to perform
poorly and continued use may cause component
damage. Extremely dirty conditions may require
that the filter be replaced more frequently.

a
a

pivot plate bolts

2 Loosen the filter bracket mounting bolt.

Disconnect the fuel hoses from the filter, then
slide the filter out of the bracket.
3 Install the new fuel filter in the bracket with the
flow direction arrow, on the filter, pointing
toward the carburetor. Tighten the bracket
mounting bolt, then reconnect the fuel hoses to
the filter.
4 Clean up any fuel that may have spilled during
the installation procedure.
5 Swing the engine pivot plate back to its original
position and replace the three retaining bolts.
6 Start the machine from the ground controls,
then inspect the fuel filter and hoses for leaks.

Engine fuels are combustible.

Replace the fuel filter in an open,
well-ventilated area away from
heaters, sparks, flames and
lighted tobacco. Always have an
approved fire extinguisher within
easy reach.

If a fuel leak is discovered, keep

any additional personnel from
entering the area and do not
operate the machine. Repair the
leak immediately.

Perform this procedure with the

engine off.

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TABLE C

PROCEDURES

C-10
Replace the PCV Valve - Gasoline/
LPG Models
Yearly replacement of the PCV valve is essential
to good engine performance. A malfunctioning
valve can impair crankcase ventilation and may
cause engine damage.
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 the PCV valve.

C-11
Clean or Replace the Distributor
Cap and Rotor - Gasoline/LPG
Models
Distributor caps and rotors that are clean and free
of damage, wear and corrosion are essential to
good engine performance and service life. A dirty
or worn cap and rotor may cause the engine to
perform poorly and continued use may cause
component damage. Extremely dirty conditions
may require that the cap and rotor be replaced
more frequently.
Perform this procedure with the
engine off.

2 Remove the hoses from the valve, then remove

the valve.
3 Install the new valve.
4 Swing engine pivot plate back to its original
position and replace the three retaining bolts.
a

a
a
a
a

pivot bolt plates

1 Remove the 3 bolts from the engine pivot plate.

Swing the engine pivot plate away from the
machine to access the distributor.
2 Label and remove the coil and spark plug wires
from the distributor cap.
3 Remove the cap and rotor from the distributor.
a
b
c

PCV valve
hose, PCV valve to carburetor
hose, PCV valve to crankcase

4 Clean the cap and rotor using electrical contact

cleaner or a damp cloth.
5 Completely dry the cap and rotor.
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.

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TABLE C PROCEDURES

7 Install the rotor and cap, then re-attach the coil

and spark plug wires.
8 Swing engine pivot plate back to its original
position and replace the three retaining pins.

C-13
Check and Adjust the
Air/Propane Mixture
Maintaining the proper air-to-fuel mixture during
propane operation is essential to good engine
performance.

C-12
Replace the Spark Plugs Gasoline/LPG Models

Engine fuels are combustible.

Perform this procedure in an
open, well-ventilated area away
from heaters, sparks, flames and
lighted tobacco. Always have an
approved fire extinguisher within
easy reach..

Periodic replacement of the spark plugs is

essential to good engine performance and service
life. Worn, loose or corroded spark plugs will
cause the engine to perform poorly and may result
in component damage.

The engine rpm needs to be

preset for gasoline fuel operation
before adjusting the propane idle
mixture.

Perform this procedure with the

engine turned off.
1 Label, then disconnect the plug wires from the
spark plugs by grasping the molded boot. Do
not pull on the plug wire.
2 Blow out any debris around spark plugs.
3 Remove all the spark plugs from the engine.

The engine should be warmed to

normal operating temperature
before performing this procedure.
1 Move the fuel select switch to propane fuel and
start the engine from the ground controls.
2 Loosen the high idle mixture adjustment lock
nut.

4 Adjust the gap on each new spark plug.

5 Install the new plugs, the reconnect the plug
wires. Be sure that each spark plug wire is
attached to the correct spark plug.

Specifications
Spark Plugs (Motorcraft)

AWSF-42

Gap

0.032 - 0.036 inches

0.81 - 0.91mm

Torque specs

5 - 10 foot-pounds
6.8 - 13.6 Nm

a
b
c
d

Part No. 29487

Genie Z-45/22

low idle mixture adjustment screw

high idle mixture adjustment screw
propane regulator
pressure adjustment

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TABLE C

PROCEDURES

3 Load the system by pressing the primary boom

extension retract switch, and then move the
engine speed control switch to high idle (rabbit
symbol).

C-14
Check and Adjust the Ignition
Timing - Gasoline/LPG Models

4 Adjust the high idle adjustment nut to obtain an

air-to-fuel mixture ratio of 13.0:1 to 13.2:1,
using an exhaust gas analyzer.

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.

If an exhaust gas analyzer is not

available, adjust to obtain peak or
optimum rpm.
5 Hold the adjustment screw and tighten the lock
nut.
6 Move the engine speed control switch to low
idle (turtle symbol) and adjust the low idle
screw to obtain an air-to-fuel mixture ratio of
13.0:1 to 13.2:1.

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Table D Procedures
7 Apply pipe thread sealant to the strainer
mounting threads, and then re-install them.

D-1
Change the Hydraulic Oil
Replacement of the hydraulic oil is essential for
good machine performance and service life. Dirty
oil and suction strainers may cause the machine to
perform poorly and continued use may cause
component damage. Extremely dirty conditions
may require oil changes to be performed more
frequently.
Perform this procedure with the
machine in the fully stowed
position.
1 Close the two hydraulic tank valves located at
the main pump.

8 Apply pipe thread sealant to the drain plug, and

then re-install it in the reservoir.
9 Re-install the two suction hoses.
10 Fill the reservoir with hydraulic oil until the level
is within the top 2 inches (5cm) of the sight
gauge. Do not overfill.
11 Clean up any oil that may have spilled and reopen the hydraulic tank valves.
12 Prime the pump by doing the following:
Gasoline/LPG models:
Disconnect the ignition coil wire and isolate it
from ground.
Diesel models:
Disconnect the wiring to the injection pump
fuel-on solenoid
All models:

open

Crank the engine with the starter motor for 15

seconds.

closed

2 Remove the drain plug from the hydraulic

reservoir.
Beware of hot oil. Contact with hot
oil may cause severe burns.

13 Reconnect the wiring and start the engine from

the ground controls. Check the hydraulic
reservoir for leaks.
Specifications

3 Completely drain the reservoir into a container.

See capacity specifications listed below.

Hydraulic tank capacity

25 gallons
95 liters

4 Disconnect and cap the two 1 inch (2.5cm)

suction hoses that are attached to the
reservoir.

Hydraulic system
capacity (including tank)

30 gallons
114 liters

Hydraulic fluid

Dexron II equivalent

5 Remove the strainer assemblies from the

reservoir.
6 Carefully clean any foreign material from the
strainers.

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TABLE D

PROCEDURES

D-2
Change or Recondition the
Engine Coolant

7 Replace all coolant hoses and clamps.

Replacing or reconditioning the engine coolant is

essential to good engine performance and service
life. Old or dirty coolant may cause the engine to
perform poorly and continued use may cause
engine damage. Extremely dirty conditions may
require coolant to be changed more frequently.

9 Disconnect hose a from hard line b and hold

until coolant starts to pour out of the open
hose. Then immediately reconnect the hose.

8 Pour the proper coolant mixture (anti-freeze &

water) for your climate into the radiator until it
is full.

Beware of hot engine parts and

coolant. Contact with hot engine
parts and/or coolant will cause
severe burns.

1 Put on protective clothing and eye wear.

2 Disconnect the coolant return hose at the
radiator and drain the coolant return tank.
3 Remove the radiator cap from the radiator.
Ford models: Remove the 3 bolts from the
engine pivot plate. Swing the engine pivot plate
away from the machine to access the radiator
petcock.

a
b

hose
hard line

10 Re-fill the radiator and then fill the coolant

recovery tank.
11 Clean up any coolant spilled during this
procedure.

4 Open the petcock on the radiator and allow

coolant to drain into a container.

12 Start the engine from the ground controls, run it

for 30 seconds, and then turn it off.
13 Inspect for leaks and then check the fluid level
in the coolant recovery tank. Add water if
needed.
a

Specifications
a

Ford Engine LSG 423

coolant capacity
a

11.5 quarts / 10.9 liters

pivot plate bolt

5 After all the coolant has drained, close the

petcock. Reconnect the coolant return hose to
the radiator.

Kubota Engine V1702-B

coolant capacity

7.25 quarts / 6.9 liters

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

Service Manual - First Edition

Section 4 - Scheduled Maintenance Procedures

TABLE D PROCEDURES

D-3
Change the Fuel Lines

Maintaining the fuel lines in good condition is

essential to safe operation and good engine
performance. Failure to detect a worn, cracked or
leaking fuel line may result in an unsafe operating
condition, poor engine performance and
component damage.
Engine fuels are combustible.
Replace the fuel lines in an open,
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.
1 Raise the primary boom, until the end of the
boom is approximately eight feet off the
ground.
2 Close the manual fuel shut off valve, located
next to the fuel tank.
3 Remove and replace the fuel line hoses
according to the following illustrations:
Fuel may be expelled under
pressure. Wrap a cloth around
fuel hoses to absorb leaking fuel
before disconnecting them. Plug
all open fuel lines.

Part No. 29487

Genie Z-45/22

Diesel models
a
hose from the injector to the fuel tank
b
hoses connecting injectors
c
hose from the injection pump to the injectors
d
hose from the fuel shutoff valve to the fuel pump
e
hose from the fuel filter/water separator
to the injection pump
f
hose from the fuel pump to the fuel/water
separator

Once air has been introduced into

the diesel fuel injection system,
the injectors must be bled before
the engine is restarted. 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.

4 - 35

Service Manual - First Edition

Section 4 - Scheduled Maintenance Procedures

TABLE D

PROCEDURES

D-4
Check Engine Valve Clearance 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.

D-5
Check Engine Cylinder
Compression - 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.

Gasoline/LPG models
a
fuel filter
b
hose from the fuel filter to the carburetor
c
hose from the fuel pump to the fuel filter
d
hose from the fuel shutoff valve to the fuel pump

4 Clean up any fuel that may have spilled during

the installation procedure.
5 Start the machine from the ground controls,
then inspect the fuel filter and hoses for leaks.
If a fuel leak is discovered, keep
any additional personnel from
entering the area and do not
operate the machine. Repair the
leak immediately.

4 - 36

Genie Z-45/22

Part No. 29487

Service Manual - First Edition

Section 4 - Scheduled Maintenance Procedures

TABLE D PROCEDURES

D-6
Clean PCV Hoses and Fittings Gasoline/LPG Models

Maintaining PCV hoses is essential to good engine

performance. Improperly functioning PCV hoses
will fail to ventilate the crankcase and continued
use of neglected hoses could result in component
damage.

Perform this procedure with the

engine off.
1 Remove the 3 bolts from the engine pivot plate.
Swing the engine pivot plate away from
machine to access the PCV hoses.

Gasoline/LPG models
(shown with distributor cap removed)
a
PCV valve
b
hose, PCV valve to carburetor
c
hose, PCV valve to crankcase

3 Clean the hoses with a mild cleaning solvent.

4 Dry both hoses and inspect them for cracks
and damage. Replace the hoses if they are
damaged.

a
a
a
a

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

Section 4 - Scheduled Maintenance Procedures

TABLE D

Service Manual - First Edition

PROCEDURES

D-7
Check the Engine Nozzle Injection
Pressure - Diesel Models
Complete information to perform this procedure is
available in the Kubota V1702-B Diesel Engine
Workshop Manual (Kubota code number: 9789700691). Genie part number 29587.

D-8
Check Injection Timing
- Diesel Models
Complete information to perform this procedure is
available in the Kubota V1702-B Diesel Engine
Workshop Manual (Kubota code number: 9789700691). Genie part number 29587.

D-9
Replace the Timing Belt - Ford
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.

4 - 38

Genie Z-45/22

Part No. 29487

Service Manual - First Edition

Part No. 29487

Section 4 - Scheduled Maintenance Procedures

Genie Z-45/22

4 - 39

Section 4 - Scheduled Maintenance Procedures

4 - 40

Genie Z-45/22

Service Manual - First Edition

Part No. 29487

Service Manual - First Edition

Section 5 - Troubleshooting Flow Charts

Chart 1
Engine Will Not
Crank Over

Check battery voltage.

Be sure the key switch

is in the appropriate
position.

Check voltage at center

terminal on start switch.

Be sure the
emergency stop button
is pulled up into the on
position.
Be sure the circuit
breaker is not tripped.

less than 12V

12V or more
0V

12V
Hold start switch and
check voltage at either
side terminal on start
switch.

Trace circuit back

through the key switch
and emergency stop
button, repair open.

0V

Replace start toggle

switch.

0V

Repair blk wire circuit

from start switch to CR1.

0V

Replace CR1 relay or

relay socket.

0V

Repair open in blk #53

wire circuit from CR1 to
PR5.

0V

Check PR5 grounding

wire OR replace PR5
relay.

0V

Replace cable from PR5

to starter.

Check battery condition

OR check alternator OR
check fro short circuits
OR check battery cables
OR replace the battery.

12V
Hold start switch and
check voltage at terminal
#1 on CR1.
12V
Check voltage at
terminal #9 on CR1.
12V
Check voltage at blk #53
on PR5.
12V
Check voltage at output
cable terminal on PR5.
12V
Check voltage at positive
cable terminal on starter
motor.
12V
Check starter ground
cable OR repair or
replace starter.
Kubota Models: Check
black jumper wire
connecting positive
cable terminal and
starter bendix terminal.

Part No. 29487

Genie Z-45/22

5-3

Service Manual - First Edition

Section 5 - Troubleshooting Flow Charts

Chart 2
Engine Cranks
Over But Will
Not Start Gasoline/LPG
Models
Be sure to check the
engine oil level and fill
as needed.

Hold start switch and

check battery voltage
while engine is cranking.

less
than
11V

more than 11V

Check if engine coolant
over-temperature light is
on?

light on

Check battery condition

OR check alternator OR
check battery cables OR
replace the battery.

Check if radiator and/or

engine block feels
excessively hot.

light not on

not hot

hot

Check engine coolant

level OR check
radiator fins for
clogging OR check
engine fan belts OR
see Ford service
manual for
troubleshooting an
overheating engine.

light
Remove blk #23 wire
Replace temperature
goes out sending unit.
from temperature
sending unit.
light stays on
Repair short in blk #23
light
Remove blk #23 wire
wire circuit from TB23
goes out to temperature
from TB23.
sending unit.
light stays on

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.

light
Remove wht/blk wire
Repair short in wht/blk
goes out (with diode) wire
from over-temperature
light.
circuit from overlight stays on
temperature light to
TB23.
Replace defective overtemperature light.

Remove #1 spark plug

and ground spark plug
body. Crank engine and
observe spark.

good
spark

Go to Chart 2A,
page 5 - 7.

weak or no spark
Disconnect and isolate
black battery cable from
the starter, hold start
switch and check voltage
at terminal H on PR5
(brown wire).

0V

Replace PR5.

12V
Continued on the next
page.

5-4

Genie Z-45/22

Part No. 29487

Service Manual - First Edition

Section 5 - Troubleshooting Flow Charts

CHART 2

Continued from the

previous page.

Hold start switch and

check voltage at positive
side of ignition coil.

0V

Repair open in brown

wire circuit from PR5 to
ignition coil.

0V

Repair open in wht wire

circuit from PR5 to
ignition module.

0V

Check diode for open

and replace OR repair
open in blk wire circuit
from PR5 to PR1.

0V

Repair open in red wire

circuit from circuit
breaker through TB20 to
PR1.

0V

Check PR1 grounding

wire circuit OR replace
PR1 relay.

12V
Hold start switch and
check voltage at wht
terminal of ignition
module.
12V
Hold start switch and
check voltage at blk wire
with diode on initiate
terminal of PR1.
12V
Check voltage at red
wire on common terminal
of PR1.
12V
Hold start switch and
check voltage at red wire
on output terminal of
PR1.
12V

light
Reconnect starter and
Check oil pressure
hold engine cranking for stays on sending unit and replace
15 seconds. Check that
OR see Ford service
oil pressure light goes
manual for
out.
troubleshooting low oil
pressure.
light goes out
Continued on the next
page.

Part No. 29487

Genie Z-45/22

5-5

Service Manual - First Edition

Section 5 - Troubleshooting Flow Charts

CHART 2

Continued from the

previous page.

Disconnect and isolate

positive cable from
starter, remove blk #22
wire from oil pressure
sending unit and
disconnect wht #51 wire
from initiate terminal of
PR1 (if equipped with
time delay relay,
disconnect wht #51 wire
from TR2 terminal #1).
Hold start switch and
check voltage at terminal
#1 on CR3.
0V
Without replacing any
wires, hold start switch
and check voltage at
terminal #9 on CR3.

12V

Reconnect blk #22 wire

to oil pressure sending
unit, wht #51 wire to PR1
initiate terminal and wht
#51 to TR2 terminal #1.
Hold start switch and
check voltage at red wire
on ignition module.

0V

Repair open in red

wire circuit from PR1
to ignition module.
Reconnect cable to
starter.

12V

0V

Reconnect blk cable to

starter and see Ford
service manual for
ignition system
troubleshooting.
Repair open in wht #52
wire circuit that connects
CR1, CR2, CR3, CR4
and CR6.

12V
Remove blk wire from
CR3 terminal #13 and
hold start switch. Check
voltage at terminal #1 on
CR3.

0V

Check CR3 grounding

wire circuit OR replace
CR3 relay OR replace
relay socket.

12V
Reconnect all wiring and
check all wires
connected to terminals
TB22 and TB23 for short
to ground and repair as
necessary.

5-6

Genie Z-45/22

Part No. 29487

Service Manual - First Edition

Section 5 - Troubleshooting Flow Charts

Chart 2A
Engine Cranks
Over But Will
Not Start Gasoline/LPG
Models

Check voltage at TB36.

Continuation of
good spark fault path
from previous flow
chart.

Disconnect blk wire from

CR2 terminal 5, crank
the engine over and
check voltage at blk #50
wire on vacuum switch.

0V

Check all diodes at

TB36 for open OR
repair open in red/blk
wire circuit from key
switch to TB36.

12V
Check voltage at blk #36
on vacuum switch.

0V

Repair open in blk #36

wire circuit from TB36 to
vacuum switch.

0V

Turn machine off and

see Repair section for
vacuum switch check.

12V

bad

Replace vacuum
switch.

OK

12V

Check vacuum line for

restrictions.

bad

Replace vacuum line.

OK
See Ford service manual
to troubleshoot low
manifold vacuum.
Disconnect wires from
vacuum switch and
connect the wires
together. Check the
voltage at terminal 5 on
CR4.

0V

Repair open in blk #50

wire circuit from vacuum
switch to CR4.

0V

Repair open in wht #52

wire circuit that connects
CR1, CR2, CR3, CR4
and CR5.

0V

Check CR4 grounding

wire circuit OR replace
CR4 relay OR replace
relay socket.

12V
Disconnect and isolate
blk positive cable from
starter. Hold start switch
and check voltage at
terminal 9 on CR4.
12V
Hold start switch and
check voltage at terminal
5 on CR5.
12V
Continued on the next
page.

Part No. 29487

Genie Z-45/22

5-7

Service Manual - First Edition

Section 5 - Troubleshooting Flow Charts

CHART 2A

Continued from the

previous page.

Hold start switch and

check voltage at center
terminal on fuel select
switch.

0V

Repair open in red/blk

wire circuit from CR4 to
fuel select toggle switch.

12V
Hold start switch and
check voltage on
gasoline side (blk/wht
wire) of fuel select
switch.
12V

0V

Hold start switch and

check voltage at terminal
TB33.

Replace toggle switch.

0V

Repair open in blk/wht

wire circuit from toggle
switch to TB33.

0V

Repair open in blk #33

wire circuit from TB33 to
anti-diesel valve.

0V

Repair open in blk #33

wire circuit from antidiesel valve to gasoline
solenoid.

12V
Hold start switch and
check voltage at blk #33
wire on anti-diesel valve
(on engine carburetor).
12V
Hold start switch and
check voltage at blk #33
wire on gasoline solenoid
(at gasoline tank).
12V
Reconnect blk positive
cable to starter, blk wire
to CR2, the two wires to
vacuum switch and
check for fuel line
blockage OR replace
anti-diesel valve OR see
Ford service manual for
troubleshooting fuel
pump and carburetor.

5-8

Genie Z-45/22

Part No. 29487

Service Manual - First Edition

Section 5 - Troubleshooting Flow Charts

Chart 3
Engine Cranks
Over But Will
Not Start Diesel Models
Be sure to check the
engine oil level and fill
as needed.
Be sure to check fuel
levels and engine
coolant level.

Hold start switch and

check battery voltage
while engine is cranking.

less
than
11V

more than 11V

Check if engine coolant
over-temperature light is
on?

light on

Check battery condition

OR check alternator OR
check battery cables OR
replace the battery.

Check if radiator and/or

engine block feels
excessively hot.

light not on

hot

not hot

Check engine coolant

level OR check
radiator fins for
clogging OR check
engine fan belts OR
see Kubota service
manual for
troubleshooting an
overheating engine.

light
Remove blk #23 wire
Replace temperature
goes out sending unit.
from temperature
sending unit.
light stays on
Repair short in blk #23
light
Remove blk #23 wire
wire circuit from TB23
goes out to temperature
from TB23.
sending unit.
light stays on

Be sure the diesel

shut-off valve is in the
on position. Be sure
engine glow plugs
operate normally, see
Maintenance section.

light
Remove wht/blk wire
Repair short in wht/blk
goes out (with diode) wire
from over-temperature
light.
circuit from overlight stays on
temperature light to
TB23.
Replace defective overtemperature light.

Hold start switch and

check if fuel solenoid
pulls in.
pulls in
Continued on the next
page.

does not Be sure solenoid has a

good ground (blk wire)
pull in
then hold start switch
and check voltage at the
wht wire on the fuel
solenoid.
12V
Check resistance of fuel
solenoid pull in coil
(wht wire).

0V

Repair open in wht

wire circuit from
starter to fuel
solenoid.

0.7
ohm

Check linkage for

mechanical
resistance.

0 or infinite ohms
Replace fuel solenoid.

Part No. 29487

Genie Z-45/22

5-9

Service Manual - First Edition

Section 5 - Troubleshooting Flow Charts

CHART 3

Continued from the

previous page.

Hold, then release the

start switch and observe
the fuel solenoid.

solenoid releases after 3 seconds

solenoid releases
immediately
Remove black jumper
wire from the starter
12V
motor solenoid, hold the
start switch and check
voltage at red wire
(hold coil) on the fuel
solenoid.
0V

Replace the fuel

solenoid (hold coil
resistance, red wire to
blk wire, should be
14.4 ohm).

Hold start switch and

check voltage at blk wire
with diode on initiate
terminal of PR1.

Check diode for open

and replace OR repair
open in blk wire circuit
from PR5 to PR1.

0V

12V
Hold start switch and
check voltage at red wire
on output terminal of
PR1.
12V

0V

Recheck fuel level,

check that fuel shut-off is
open and check that fuel
filter is free of water and
debris.
OK
Bleed fuel injectors OR
refer to Kubota service
manual to troubleshoot
fuel injection pump.

Repair open in red wire

supplying 12V to PR1
common terminal OR
check PR1 ground OR
replace PR1 relay.

light
Reconnect starter and
Check oil pressure
hold engine cranking for stays on sending unit and replace
OR see Kubota service
15 seconds. Check that
oil pressure light goes
manual for
troubleshooting low oil
out.
pressure.
light goes out
Remove the wht #51
wire from CR4 terminal
5, hold start switch and
check voltage at terminal
5 on CR4.

12V

Repair open in wht #51

wire circuit from CR4
terminal 5 to PR1.

0V

Replace CR4 relay or

relay socket.

0V
Repair open in wht #51
wire circuit from CR4
terminal 5 to PR1.
12V
Replace TR2 time delay
relay.

5 - 10

Genie Z-45/22

Part No. 29487

Service Manual - First Edition

Section 5 - Troubleshooting Flow Charts

Chart 4
Engine Choke
Inoperative Gasoline/LPG
Models
Be sure machine is
equipped with manual
choke.

Check voltage at
common terminal of PR4

0V

Repair open in black

cable supplying 12V to
PR4.

0V

Hold choke switch and

check voltage at red wire
on choke solenoid.

12V
Hold choke switch and
check voltage at red wire
(normally open) terminal
of PR4.

12V

Be sure choke
solenoid to carburetor
linkage is in place and
properly attached.
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.

Check solenoid ground.

0V

Repair open in red

wire circuit from PR4
to choke solenoid.

bad

Repair open in green

grounding wire circuit.

good
Replace solenoid.
Note: Resistance across
solenoid terminals
should be approximately
0.3 ohms.

Check voltage on center

terminal of choke switch.

0V

Repair open in circuit

supplying 12V to choke
switch.

12V
Hold choke switch and
check voltage at org/red
wire on toggle switch.

0V

Replace toggle switch.

12V
Hold choke switch and
check voltage at red wire
on center terminal of fuel
select switch.

0V

Repair open in red wire

circuit from choke switch
to fuel select switch.

12V
Hold choke switch and
check voltage at blk/wht
wire on fuel select
switch.
12V

0V

Replace fuel select

switch.

Continued on the next

page.

Part No. 29487

Genie Z-45/22

5 - 11

Service Manual - First Edition

Section 5 - Troubleshooting Flow Charts

CHART 4

Continued from the

previous page.

Hold choke switch and

check voltage at TB29.

0V

Repair open in blk/wht

wire circuit from fuel
select switch to TB29.

0V

Repair open in blk #29

wire circuit from TB29 to
PR4.

bad

Repair open in green

grounding wire circuit.

12V
Hold choke switch and
check voltage at initiate
terminal of PR4.
12V
Check green grounding
wire circuit for PR4.
OK
Replace PR4.

5 - 12

Genie Z-45/22

Part No. 29487

Service Manual - First Edition

Section 5 - Troubleshooting Flow Charts

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.

Disconnect LPG supply

line from LPG tank and
bleed pressure from line.

Disconnect and isolate

black positive cable from
starter motor, hold start
switch and check voltage
at LPG side (blu/red
wire)of fuel select switch.

0V

Replace fuel select

switch.

12V
Hold start switch and
check voltage at TB34.

0V

Repair open in blu/red

wire circuit from fuel
select switch to TB34.

0V

Repair open in blk #34

wire circuit from TB34 to
LPG solenoid.

bad

Repair green grounding

wire circuit.

12V
Hold start switch and
check voltage at blk #34
wire on LPG solenoid.
12V
Check green grounding
wire circuit for LPG
solenoid.
OK
Move start switch on and
off repeatedly. Listen to
and feel LPG solenoid
for click.

no click

Replace LPG solenoid.

solenoid clicks
Reconnect LPG tank and
see Maintenance section
for LPG adjustments.

Part No. 29487

Genie Z-45/22

5 - 13

Service Manual - First Edition

Section 5 - Troubleshooting Flow Charts

Chart 7
Engine Will Not
Start on
Gasoline, But
Will Start on
LPG
- 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.

Disconnect and isolate

black positive cable from
starter motor, hold start
switch and check voltage
at gasoline side (blu/wht
wire)of fuel select switch.

0V

Replace fuel select

switch.

12V
Hold start switch and
check voltage at TB33.

0V

Repair open in blu/wht

wire circuit from fuel
select switch to TB33.

0V

Repair open in blk #33

wire circuit from TB33 to
anti-diesel valve.

0V

Repair open in blk #33

wire circuit from antidiesel valve to fuel
solenoid.

bad

Repair green grounding

wire circuit.

no click

Replace gasoline
solenoid.

12V
Hold start switch and
check voltage at blk #33
wire on anti-diesel valve
(on carburetor).
12V
Hold start switch and
check voltage at blk #33
wire on anti-gasoline
solenoid (at fuel tank).
12V
Check green grounding
wire circuit for gasoline
solenoid.
OK
Move start switch on and
off repeatedly. Listen- to
and feel gasoline
solenoid for click.

solenoid clicks
Reconnect black cable
to starter, check antidiesel for defects OR
see Ford service manual
for carburetor
troubleshooting.

5 - 14

Genie Z-45/22

Part No. 29487

Service Manual - First Edition

Section 5 - Troubleshooting Flow Charts

Chart 8
Engine High
Idle Inoperative
- Gasoline/LPG
Models
If high idle operates on
LPG but not on
gasoline, see Ford
service manual for
carburetor
troubleshooting.
If high 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.
Be sure high idle can
be achieved by
grasping the governor
actuator arm and
momentarily pulling to
throttle the carburetor.

Start engine and switch

rpm select to high idle
(rabbit symbol). Check
voltage at blk/red wire on
rpm switch.

0V

Check voltage at center

terminal on rpm select
switch.
12V

0V

Repair open in circuit

supplying 12V to
center terminal of
switch.

Replace rpm select

toggle switch.

12V

Check voltage at TB30.

0V

Repair open in blk/red

wire circuit from toggle
switch to TB30.

0V

Repair open in blk #30

wire circuit from TB30 to
PR2.

bad

Repair open in green

grounding wire.

0V

Repair open in wht wire

circuit from PR1 to
governor actuator.

12V
Check voltage at initiate
terminal (blk #30 wire) of
PR2.
12V
Check PR2 green
grounding wire.
OK
Check voltage at
terminal 1 (wht wire) on
governor actuator.
12V

Turn off engine,

disconnect blk wire from
terminal #4 on electronic
governor and disconnect no
continuity
wht wire from governor
Replace PR2.
actuator. Restart engine,
switch to high idle and
check continuity
between loose blk wire
and blk wire terminal of
governor actuator.
full continuity
Continued on the next
page.

Part No. 29487

Genie Z-45/22

5 - 15

Service Manual - First Edition

Section 5 - Troubleshooting Flow Charts

CHART 8

Continued from the

previous page.

Check resistance across

governor actuator
terminals.

0 or infinite ohms

Replace governor
actuator.

2 to 3 ohms
Check voltage at
terminal #1 on electronic
governor.
12V

0V

Repair open in wht wire

circuit from PR1 to
electronic governor.

Check electronic
governor green
grounding wire (terminal
2).
OK

bad

Repair open in green

wire grounding circuit.

Check voltage at
governor terminal 3
(yellow wire).
6 to 7V

0V

Repair open in yellow

wire circuit from ignition
module to electronic
governor.

Reconnect all wires and

see Maintenance section
for governor adjustments
OR replace electronic
governor.

5 - 16

Genie Z-45/22

Part No. 29487

Service Manual - First Edition

Section 5 - Troubleshooting Flow Charts

Chart 9
Engine Low
Idle Inoperative
- Gasoline/LPG
Models
If low idle operates on
LPG but not on
gasoline, see Ford
service manual for
carburetor
troubleshooting.

Start engine and switch

rpm select to low idle
(turtle symbol). Check
voltage at blk/red wire on
rpm switch.

12V

0V
Check voltage at blk #30
wire on PR2.

12V

0V

Remove blk/red wire

(with diode) from PR2
initiate terminal and
check voltage at blk #30
wire on PR2.

12V

Repair short in blk

#30 wire.

0V

Repair short in blk/red

wire circuit.

0V

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.

Isolate ground and

platform rpm switches,
check individually and
replace defective switch.

Check voltage at blk/red

wire on PR5.
12V
Blk/red wire has short
OR if engine will not
cranking, PR5 is
defective.
Remove both blk wires
from PR2 and check
continuity across open
terminals.

no
Recheck throttle linkage
continuity (see Repair section) OR
see Ford service manual
for carburetor
troubleshooting.

full continuity
Replace PR2 relay.

Part No. 29487

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5 - 17

Service Manual - First Edition

Section 5 - Troubleshooting Flow Charts

Chart 10
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.

Start engine, switch rpm

select switch to high idle
(rabbit symbol) and
check if 2-speed
solenoid pulls in.

Check high idle

adjustment (see
Maintenance section) or
see Kubota workshop
manual to troubleshoot
fuel injector pump.

solenoid pulls in

solenoid does not pull in

Check voltage at blk/red
wire on rpm select
switch.
12V

0V

Check voltage on center

terminal of rpm select
switch.

0V

Repair open in circuit

supplying 12V to center
terminal of switch.

12V
Replace toggle switch.

Check voltage at TB30.

0V

Repair open in blk/red

wire circuit from toggle
switch to TB30.

0V

Repair open in blk #30

wire circuit from TB30 to
PR2.

12V
Check voltage at initiate
terminal (blk #30 wire) on
PR2.
12V
Check voltage at the red
wire on the 2-speed
solenoid.

0V

Replace PR2 relay or

repair open in red wire
circuit from PR2 to
2-speed solenoid.

12V

solenoid
Check if 2-speed
binds
solenoid moves in and
out freely.
moves freely

Check linkage or replace

solenoid.

Replace 2-speed
solenoid. Note:
resistance across
solenoid terminals
should be approximately
0.3 ohms.

5 - 18

Genie Z-45/22

Part No. 29487

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.

At platform controls,
start engine and switch
rpm select switch to
maintained low idle
(turtle symbol). Check
volts at blk/red wire on
rpm select switch.

12V

Isolate the platform and

ground rpm switches,
check individually and
replace defective switch.

0V
Check voltage at the red
wire on the 2-speed
solenoid.

12V

Replace PR2 relay.

0V

solenoid
binds
Check if 2-speed
solenoid moves in and
out freely.
moves freely

Check linkage or replace

solenoid.

Check adjustment of
linkage and fuel injection
pump low idle (see
Maintenance section).
OK
See Kubota workshop
manual to troubleshoot
fuel injection pump.

Part No. 29487

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5 - 19

Service Manual - First Edition

Section 5 - Troubleshooting Flow Charts

Chart 12
All Functions
Inoperative,
Engine Starts
and Runs

low

Check hydraulic fluid

level.
OK
Check pump suction line
shutoff valves, Valve
handles should be
parallel with hose.

closed

Fill with Dexron II

equivalent hydraulic
fluid.
Open valves. If engine
has been run with valves
closed, it may have
damaged one or both
pumps.

open
Disconnect center coil
wire from distributor cap
spline
and isolate from
turns
grounding. Remove
function pump from drive
pump but leave all hoses
connected. Hold start
switch and crank engine
over while observing
spline drive at rear of
drive pump.
spline does not turn

Troubleshoot inoperative
boom functions and
inoperative drive
functions separately.

Engine to pump flex

plate coupling is
defective. See Repair
section.

5 - 20

Genie Z-45/22

Part No. 29487

Service Manual - First Edition

Section 5 - Troubleshooting Flow Charts

Chart 13
All Lift and
Steer
Functions
Inoperative,
Drive
Functions
Operational
Be sure the hydraulic
suction line shutoff
valve for the lift/steer
pump is in the open
position.
Be sure all grounding
wires for the hydraulic
manifold valves are
free of corrosion and
have full continuity to
ground.

Start engine, hold the

platform rotate function
and check the hydraulic
pressure at the quick
disconnect fitting on the
turntable function
manifold.

2000 PSI or more

Troubleshoot each
function individually or
consult Genie Industries
service department.

less than 2000 PSI

Adjust the function
manifold relief valve
(item AF) all the way in
2000 PSI or more
(clockwise) counting the
number of turns. Hold
the platform rotate
switch and recheck the
pressure.
less than 2000 PSI Replace the relief valve
OR manifold has internal
OK
Check the function
defects, consult Genie
pump, see Repair
Industries service
section.
department.
bad

Hold the platform rotate

switch and readjust the
relief pressure to 2200
PSI.

Replace the pump.

Part No. 29487

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5 - 21

Service Manual - First Edition

Section 5 - Troubleshooting Flow Charts

Chart 14
yes

Ground
Controls
Inoperative,
Platform
Controls
Operate
Normally

Does the engine start

from the ground
controls?
no

Be sure all other

functions operate
normally, including
platform controls.

Check voltage at red

wire on ground controls
contact of the key switch
(the red wire checked
should originate at the
emergency stop button).

Start the engine from the

ground controls and
check the voltage on the
center pole (red wire) of
the platform level switch.

0V

Repair open in red

wire circuit from key
switch to function
switches.

yes

Replace key switch

contact for ground
controls.

12V
Troubleshoot the
functions individually.

0V

Repair open in red wire

circuit from emergency
stop button to the key
switch.

12V
Check voltage at red/wht
#36 wire at ground
controls contact on the
key switch.

Check if key switch

internal cam is activating
ground contact.
no

12V
Repair open in red wire
circuit from key switch to
function switches.

5 - 22

0V

Replace key switch.

Genie Z-45/22

Part No. 29487

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.

Does engine start from

the platform controls?

yes

no

Start engine from the

platform, then press
down the foot switch and
check voltage at TP20.
12V

0V

Repair open in wht

wire circuit from foot
switch to TP20 OR
test and replace foot
switch.

Repair open in wht wire

circuit from TP20 to
function controllers.

Check voltage at TB19.

0V

12V

Check voltage at TP34

and TP25.

0V

Repair open in red-1 and

red-2 wire circuit from
TB19 to TP34 and TP25
respectively.

0V

Replace contact on
emergency stop button.

0V

Repair open in blk wire

circuit from emergency
stop button to TP22.

12V
Check voltage at blk wire
on platform emergency
stop button.
12V
Check voltage at TP22.
12V

Check for open in red

wire circuit from key
switch to TB19 OR
replace the key switch
platform contacts.

Repair open in blk wire

circuit from TP22 to foot
switch OR replace foot
switch.

Part No. 29487

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5 - 23

Service Manual - First Edition

Section 5 - Troubleshooting Flow Charts

Chart 16
Secondary
Boom Up
Function
Inoperative
Perform this test only if
the boom is in the fully
lowered position.
Be sure all other
functions operate
normally.
If secondary boom up
function operates
normally from the
ground controls but not
from the platform
controls, troubleshoot
the platform controller.
See Repair section.
If secondary boom up
function operates
normally from the
platform controls but
not from the ground
controls, troubleshoot
the ground control
toggle switch. See
Repair section.
Note: Oscillating axle
equipped models, from
the stowed position the
auxiliary power can not
raise the boom above
the drive limit switch.
Auxiliary power can
raise the boom if it is
already raised above
the drive limit switch.

5 - 24

With engine running and

boom in fully stowed
position, hold the primary
up function and check if
the boom will raise up to
the drive limit switch.

raises and stops but will not

continue

See Oscillate Lockout Function Is

Malfunctioning
troubleshooting
flow chart.

no movement
Hold ground control
function switch and
check volts at blu/wht
wire on secondary
function proportional
valve.
3 to 6V
Remove both wires from
valve coil and check
resistance across the
coil terminals.

0V

Repair open in blu/wht

wire circuit from TB12 to
proportional valve.

0 or infinite ohms

Replace coil.

4.5 to 5.5 ohms

Hold toggle switch up
and manually override
proportional valve (push
in button on end of valve
spool). Note: overriding
the valve will require two
people. If a helper is not
available, interchange
the valve (item I) with a
like valve (item H).

function operates

Replace the
proportional valve.

function inoperative
Interchange secondary
function flow regulator
valve (item N) with a like
valve (item M).

function operates

Replace defective flow

regulator valve.

function inoperative
Continued on the next
page.

Genie Z-45/22

Part No. 29487

Service Manual - First Edition

Section 5 - Troubleshooting Flow Charts

CHART 16

Continued from the

previous page.

Hold toggle switch up

and manually override
directional valve (push in
button on end of valve
spool). Note: overriding
the valve will require two
people. If a helper is not
available, interchange
the valve (item C) with a
like valve (item B).

function
operates

Check the resistance of

both directional valve
coils.

4 to 5
ohms

Replace the valve.

0 or infinite ohms
Replace the defective
valve coil(s).

function inoperative
Install a pressure gauge
at the quick disconnect
coupling on the function
manifold and hold the
function switch.

2000 PSI

Check for mechanical

restriction keeping
secondary from
moving.

less than 2000 PSI

Remove and cap the up
function (steel) pressure
line attached to the
cylinder on the fuel tank
side. Then, with pressure
gauge still attached,
operate the function up.

2000 PSI

Repair the cylinder

that was
disconnected.

less than 2000 PSI

Reconnect the cylinder.
Then disconnect up
function high pressure
hose and the fitting from
the engine side cylinder
and install into the other 2000 PSI
cylinder in place of
plugged port. Remove
and cap the up function
(steel) pressure line
attached to the cylinder
on the engine side.
Then, with pressure
gauge still attached,
operate the function up.
less than 2000 PSI

Repair the cylinder

that was
disconnected.

Continued on the next

page.

Part No. 29487

Genie Z-45/22

5 - 25

Service Manual - First Edition

Section 5 - Troubleshooting Flow Charts

CHART 16

Continued from the

previous page.

Re-install all hydraulic

lines in the original
configuration then
2000 PSI
remove and cap the
function up pressure line
port (R1) on the manifold
OR cap the hose at the
point the hose connects
to the engine side
cylinder on the. Hold
function switch up and
check pressure.
less than 2000 PSI

Repair both secondary

function cylinders.

One of the previous tests

involving the pump or
manifold components
was possibly overlooked
or diagnosed incorrectly.
Recheck and/or consult
Geinie Industries service
department.

5 - 26

Genie Z-45/22

Part No. 29487

Service Manual - First Edition

Section 5 - Troubleshooting Flow Charts

Chart 17
Secondary
Boom Down
Function
Inoperative
Be sure all other
functions operate
normally including
secondary up function.
If secondary boom
down function operates
normally from the
ground controls but not
from the platform
controls, troubleshoot
the platform controller.
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.

Hold ground control

function switch and
check volts at blu/blk
wire on secondary
function directional
valve.
12V

0V

Hold toggle switch down

and manually override
the down directional
valve (push in button on
end of valve spool).
Note: overriding the
valve will require two
people. If a helper is not
available, interchange
the valve (item C) with a
like valve (item B).

Repair open in blu/wht

wire circuit from TB11 to
directional valve.

function
operates Check the resistance of
the down directional
valve coil.

4 to 5
ohms

Replace the valve.

0 or infinite ohms

Check for mechanical

restrictions and/or a
condition exists in
which the cylinder(s)
function does not operate
counterbalance valves
Install a pressure gauge 1200
Counting the turns,
function are not allowing the
PSI
inoperative cylinders to retract or
at the quick disconnect
adjust the secondary
the cylinders have
coupling on the function
down relief valve (item
internal defects.
manifold and hold the
U) in all the way. Then,
Disconnecting
function down switch.
operate the function
hydraulic lines or
down.
adjusting the cylinder
less than 1200 PSI
function
counterbalance valves
operates
With secondary boom
in this situation can be
fully lowered, hold the
very dangerous
Please consult Genie
function down switch.
Adjust the relief valve to
Industries service
read 1200 PSI and
department.
replace the
counterbalance valves.
Adjust the secondary
With secondary boom
down relief valve (item
fully lower, hold the
U) in one turn clockwise. 1200 PSI or more
function down switch.
Then, with pressure
Adjust the relief valve
gauge still attached, hold
to read 1200 PSI.
the function down
switch.
less than 1200 PSI
Replace the coil.

Continued on the next

page.

Part No. 29487

Genie Z-45/22

5 - 27

Service Manual - First Edition

Section 5 - Troubleshooting Flow Charts

CHART 17

Continued from the

previous page.

Interchange secondary
relief valve (item U) with
like valve (item T). Hold
secondary down function
and recheck pressure.

1200 PSI

Replace defective valve.

less than 1200 PSI

If secondary boom is in
stowed position, remove
and plug the secondary
down high pressure line
from the cylinder on the
fuel tank side of the
machine. Hold
secondary down function
and recheck pressure.

1200 PSI

Repair both secondary

function cylinders.

less than 1200 PSI

Internal defect in
manifold OR one of the
previous tests involving
the pump or manifold
components was
possibly overlooked or
diagnosed incorrectly.
Recheck and/or consult
Genie Industries service
department.

5 - 28

Genie Z-45/22

Part No. 29487

Service Manual - First Edition

Section 5 - Troubleshooting Flow Charts

Chart 18
Primary Boom
Up Function
Inoperative
Be sure all other
functions operate
normally.
If primary boom up
function operates
normally from the
ground controls but not
from the platform
controls, troubleshoot
the platform controller.
See Repair section.
If primary boom up
function operates
normally from the
platform controls but
not from the ground
controls, troubleshoot
the ground control
toggle switch. See
Repair section.
Note: Oscillating axle
equipped models, from
the stowed position the
auxiliary power can not
raise the boom above
the drive limit switch.
Auxiliary power can
raise the boom if it is
already raised above
the drive limit switch.

With engine running and

boom in fully stowed
position, hold the primary
up function and check if
the boom will raise up to
the drive limit switch.

raises and stops but will not

continue

See Oscillate Lockout Function Is

Malfunctioning
troubleshooting flow
chart.

no movement
Hold ground control
function switch and
check volts at red/wht
wire on primary function
proportional valve.

0V

Repair open in red/wht

wire circuit from TB3 to
proportional valve.

3 to 6V
Remove both wires from
valve coil and check
resistance across the
coil terminals.

0 or infinite ohms

Replace coil.

4.5 to 5.5 ohms

Hold toggle switch up
and manually override
proportional valve (push
in button on end of valve
spool). Note: overriding
the valve will require two
people. If a helper is not
available, interchange
the valve (item H) with a
like valve (item I).

function operates

Replace the
proportional valve.

function inoperative
Interchange primary
function flow regulator
valve (item M) with a like
valve (item L).

function operates

Replace defective flow

regulator valve.

function inoperative
Continued on the next
page.

Part No. 29487

Genie Z-45/22

5 - 29

Service Manual - First Edition

Section 5 - Troubleshooting Flow Charts

CHART 18

Continued from the

previous page.

Hold toggle switch up

and manually override
directional valve (push in
button on end of valve
spool).

function
operates

function inoperative
Install a pressure gauge
at the quick disconnect
coupling on the function
manifold and hold the
function switch.

4 to 5
Check the resistance of
ohms
the directional valve
coils.
0 or infinite ohms

Replace the valve.

Replace the defective

valve coil(s).

2000 PSI

Check for mechanical

restrictions keeping
primary boom from
moving.

less than 2000 PSI

Remove the up function
pressure line from the
manifold and cap the
2000 PSI
port (P1). Then, with
pressure gauge still
attached, operate the
function up.
less than 2000 PSI
One of the previous tests
involving the pump or
manifold components
was possibly overlooked
or diagnosed incorrectly.
Recheck and/or consult
Geinie Industries service
department.

5 - 30

Genie Z-45/22

Interchange the
primary lift cylinder
counter-balance valve
with a like valve from
one of the secondary
cylinders.
function
inoperative
Repair the cylinder.

Part No. 29487

Service Manual - First Edition

Section 5 - Troubleshooting Flow Charts

Chart 19
Primary Boom
Down Function
Inoperative
Be sure all other
functions operate
normally including
primary up function.
If primary boom down
function operates
normally from the
ground controls but not
from the platform
controls, troubleshoot
the platform controller.
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.

Hold ground control

function switch and
check volts at red/blk
wire on primary function
directional valve.

0V

Repair open in red/blk

wire circuit from TB2 to
directional valve.

12V
Hold toggle switch down
and manually override
the down directional
valve (push in button on
end of valve spool).
Note: overriding the
valve will require two
people. If a helper is not
available, interchange
the valve (item B) with a
like valve (item C).

function
operates Check the resistance of
the down directional
valve coil.

4 to 5
ohms

Replace the valve.

0 or infinite ohms

Check for mechanical

restrictions and/or a
condition exists in
which the cylinder
function inoperative
counterbalance valve
Install a pressure gauge 1200
Counting the turns,
function is not allowing the
PSI
at the quick disconnect
adjust the primary down inoperative cylinder to retract or
the cylinder has
coupling on the function
relief valve (item T) in
internal defects.
manifold and hold the
all the way. Then,
Disconnecting
function switch.
operate the function
hydraulic lines or
down.
adjusting the cylinder
less than 1200 PSI
function
counterbalance valve
operates
With primary boom fully
in this situation can be
lowered, hold the
very dangerous
Please consult Genie
function down switch.
Adjust the relief valve to
Industries service
read 1200 PSI and
department.
replace the
counterbalance valve.
Adjust the primary down
With primary boom
relief valve (item T) in
fully lower, hold the
1200 PSI or more
one turn clockwise.
function down switch.
Then, with pressure
Adjust the relief valve
gauge still attached,
to read 1200 PSI.
operate the function
down.
less than 1200 PSI
Replace the coil.

Continued on the next

page.

Part No. 29487

Genie Z-45/22

5 - 31

Service Manual - First Edition

Section 5 - Troubleshooting Flow Charts

CHART 19

Continued from the

previous page.

Interchange primary
relief valve (item T) with
like valve (item U). Hold
primary down function
and recheck pressure.

1200 PSI

Replace defective valve.

less than 1200 PSI

Remove the primary
down high pressure line
from the manifold and
cap the port (P2). Hold
primary down function
and recheck pressure.

1200 PSI

Repair the primary

function cylinder.

less than 1200 PSI

Internal defect in
manifold OR one of the
previous tests involving
the pump or manifold
components was
possibly overlooked or
diagnosed incorrectly.
Recheck and/or consult
Genie Industries service
department.

5 - 32

Genie Z-45/22

Part No. 29487

Service Manual - First Edition

Section 5 - Troubleshooting Flow Charts

Chart 20
Primary Boom
Extend
Function
Inoperative
Be sure all other
functions operate
normally.
If primary boom extend
function operates
normally from the
ground controls but not
from the platform
controls, troubleshoot
the platform controller.
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.

0V

Hold ground control

function switch and
check volts at blk/red
wire on extend/retract
proportional valve.
3 to 6V
Remove both wires from
valve coil and check
resistance across the
coil terminals.

0 or infinite ohms

Replace the coil.

4 to 5 ohms
Hold toggle switch up
and manually override
proportional valve (push
in button on end of valve
spool). Note: overriding
the valve will require two
people. If a helper is not
available, interchange
the valve (item G) with a
like valve (item H).

function operates

Replace the
proportional valve.

function inoperative
Interchange extend/
function operates
retract flow regulator
valve
(item L) with a like valve
(item M).
function inoperative
Hold toggle switch up
and manually override
extend directional valve
(push in button on end of
valve spool).

function
operates

function inoperative
Continued on the next
page.

Part No. 29487

Repair open in blk/red

wire circuit from TB9 to
proportional valve.

Replace defective flow

regulator valve.

Check the resistance of

the directional valve coil.

4 to 5
ohms

Replace the valve.

0 or infinite ohms
Replace the defective
valve coil.

Genie Z-45/22

5 - 33

Service Manual - First Edition

Section 5 - Troubleshooting Flow Charts

CHART 20

Continued from the

previous page.

Install a pressure gauge

at the quick disconnect
coupling on the function
manifold and hold the
function switch.

2000
PSI

less than
2000 PSI

If primary is extended
function
operates
one inch or more,
interchange the
accessible
counterbalance valve
with like valve from a
secondary lift cylinders.
Re-test function. If valve
is inaccessible continue
with function inoperative.
function inoperative

Replace defective
counterbalance valve.

Check for mechanical

restrictions OR the
cylinder has internal
defects OR replace
counterbalance valve.
Please consult Genie
Industries service
department.
Remove the extend
function pressure line
from the manifold and
cap the port (EXTEN.).
Then, with pressure
gauge still attached,
operate the function up.

2000
PSI

Repair the cylinder and/

or replace cylinder
counterbalance valves.

less than 2000 PSI

Internal defect in
manifold OR one of the
previous tests involving
the pump or manifold
components was
possibly overlooked or
diagnosed incorrectly.
Recheck and/or consult
Geinie Industries service
department.

5 - 34

Genie Z-45/22

Part No. 29487

Service Manual - First Edition

Section 5 - Troubleshooting Flow Charts

Chart 21
Primary Boom
Retract
Function
Inoperative
Be sure all other
functions operate
normally including
primary extend
function.
If primary boom retract
function operates
normally from the
ground controls but not
from the platform
controls, troubleshoot
the platform controller.
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.

Hold ground control

function switch and
check volts at blk/wht
wire on extend/retract
function valve.

0V

Repair open in blk/wht

wire circuit from TB8 to
directional valve.

12V
Hold toggle switch down
and manually override
the retract directional
valve (push in button on
end of valve spool).
Note: overriding the
valve will require two
people. If a helper is not
available, interchange
the valve (item A) with a
like valve (item B).

function
operates

Check the resistance of

the down directional
valve coil.

4 to 5
ohms

Replace the valve.

0 or infinite ohms
Replace the defective
valve coil.

function inoperative
Install a pressure gauge
at the quick disconnect
coupling on the function
manifold and hold the
function switch.

2000
PSI

less than 2000 PSI

Remove the primary

2000
retract high pressure line PSI
from the manifold and
cap the port (RETRACT).
Hold primary retract
function and recheck
pressure.
less than 1200 PSI

Check for mechanical

restrictions OR a
condition exists in which
the cylinder
counterbalance valve is
not allowing the cylinder
to retract or the cylinder
has internal defects.
Please consult Genie
Industries service
department.

Repair the extend/retract

function cylinder.

Internal defect in
manifold OR one of the
previous tests involving
the pump or manifold
components was
possibly overlooked or
diagnosed incorrectly.
Recheck and/or consult
Genie Industries service
department.

Part No. 29487

Genie Z-45/22

5 - 35

Service Manual - First Edition

Section 5 - Troubleshooting Flow Charts

Chart 22
Turntable
Rotate
Function
Inoperative
Be sure all other
functions operate
normally.
If turntable rotate
function operates
normally from the
ground controls but not
from the platform
controls, troubleshoot
the platform controller.
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.

Hold ground control

function switch and
check volts at wht/red
wire on turntable rotate
function proportional
valve.
4 to 7V

0V

Repair open in wht/red

wire circuit from TB6 to
proportional valve.

Remove both wires from

valve coil and check
resistance across the
coil terminals.

0 or infinite ohms

Replace coil.

4.5 to 5.5 ohms

Hold toggle switch up
and manually override
proportional valve (push
in button on end of valve
spool).

function
operates Replace the proportional
valve.

function inoperative
Interchange primary
function flow regulator
valve (item O) with a like
valve (item M).

function
operates Replace defective flow
regulator valve.

function inoperative
Hold toggle switch to left
and manually override
rotate left directional
valve (push in button on
end of valve spool).

function
4 to 5
operates Check the resistance of
ohms
the directional valve
coils.
0 or infinite ohms

function inoperative

Replace the valve.

Replace the defective

valve coil(s).

Continued on the next

page.

5 - 36

Genie Z-45/22

Part No. 29487

Service Manual - First Edition

Section 5 - Troubleshooting Flow Charts

CHART 22

Continued from the

previous page.

Install a pressure gauge

at the quick-disconnect
coupling on the function
manifold and hold the
function switch.

2000
PSI

less than 2000 PSI

less than 2000 PSI
Remove the left function
pressure line from the
manifold and cap the
2000
port (S2). Then, with
PSI
pressure gauge still
attached, operate the
function left.
less than 2000 PSI

Interchange sandwich
block including
counterbalance valves
with leveling sandwich
block.
function
operates
Replace defective
sandwich block with
counterbalance valves.

function Check for mechanical

inoperative restrictions keeping
turntable from rotating
OR repair rotation
motor OR replace
directional valve.

Repair or replace the

rotation motor.

Replace the directional

valve OR the manifold
has internal defects OR
one of the previous tests
was possibly overlooked
or diagnosed incorrectly.
Recheck and/or consult
Geinie Industries service
department.

Part No. 29487

Genie Z-45/22

5 - 37

Service Manual - First Edition

Section 5 - Troubleshooting Flow Charts

Chart 23
Turntable
Rotate Left
Function
Inoperative

Hold ground control

function switch and
check volts at wht wire
on rotate function
directional valve.
12V

0V

Be sure all other

functions operate
normally including
turntable rotate right
function.

Remove both wires from

rotate left valve coil and
check resistance across
the coil terminals.

0 or infinite ohms

If turntable rotate left

function operates
normally from the
ground controls but not
from the platform
controls, troubleshoot
the platform controller.
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.

Replace the valve

coil.

4 to 5 ohms
Hold toggle switch left
and manually override
function
rotate left directional
operates Replace the rotate
valve (push in button on
directional valve.
end of valve spool).
Note: overriding the
valve will require two
people.
function inoperative
Install a pressure gauge
at the quick-disconnect
coupling on the function
manifold and hold the
function switch.

2000
PSI

less than 2000 PSI

Remove the rotate left

function pressure line
from the manifold and
cap the port (S2). Then,
with pressure gauge still
attached, operate the
function.

2000
PSI

less than 2000 PSI

Replace the directional
valve OR the manifold
has internal defects OR
one of the previous tests
was possibly overlooked
or diagnosed incorrectly.
Recheck and/or consult
Geinie Industries service
department.

5 - 38

Repair open in wht wire

circuit from TB4 to
directional valve.

Interchange the rotate

left and right
counterbalance valves in
the sandwich block.

function
operates

Replace defective
counterbalance valve.

function inoperative
Check for mechanical
restrictions keeping
turntable from rotating
left OR replace
directional valve OR
repair rotation motor.
Check for mechanical
restrictions keeping
turntable from rotating
left OR repair rotation
motor.

Genie Z-45/22

Part No. 29487

Service Manual - First Edition

Section 5 - Troubleshooting Flow Charts

Chart 24
Turntable
Rotate Right
Function
Inoperative
Be sure all other
functions operate
normally including
turntable rotate left
function.
If turntable rotate right
function operates
normally from the
ground controls but not
from the platform
controls, troubleshoot
the platform controller.
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.

Hold ground control

function switch and
check volts at wht/blk
wire on rotate function
directional valve.

0V

Repair open in wht/blk

wire circuit from TB5 to
directional valve.

12V
Remove both wires from
rotate right valve coil and
check resistance across
the coil terminals.

0 or infinite ohms

Replace the valve

coil.

4 to 5 ohms
Hold toggle switch right
function
and manually override
operates Replace the rotate
rotate right directional
valve (push in button on
directional valve.
end of valve spool).
Note: overriding the
valve will require two
people.
function inoperative
Interchange the rotate
Install a pressure gauge 2000
function
right and left
at the quick-disconnect
PSI
operates Replace defective
counterbalance valves in
coupling on the function
counterbalance valve.
the sandwich block.
manifold and hold the
function switch.
function inoperative
less than 2000 PSI
Remove the rotate right
function pressure line
from the manifold and
cap the port (S1). Then,
with pressure gauge still
attached, operate the
function.

2000
PSI

less than 2000 PSI

Check for mechanical

restrictions keeping
turntable from rotating
right OR replace
directional valve OR
repair rotation motor.
Check for mechanical
restrictions keeping
turntable from rotating
right OR repair rotation
motor.

Replace the directional

valve OR the manifold
has internal defects OR
one of the previous tests
was possibly overlooked
or diagnosed incorrectly.
Recheck and/or consult
Geinie Industries service
department.

Part No. 29487

Genie Z-45/22

5 - 39

Service Manual - First Edition

Section 5 - Troubleshooting Flow Charts

Chart 25
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.

Remove both hydraulic

hoses from the manifold
(ports PL1 & PL2). Plug
the hoses and cap the
manifold fittings. Operate
primary boom up
function and check if
platform levels?

yes

Replace the
counterbalance valves in
the sandwich block
(items Z & AZ).

no
Plumb a pressure gauge
into the barrel-end
2000 PSI
hydraulic hose using a
tee fitting, Operate
primary boom up
function and read the
pressure.
less than 2000 PSI
Deadhead the pressure
gauge into the barrel-end
hydraulic hose from the
master cylinder and raise
2000 PSI or more
the primary boom one
inch at a time.
Continually monitor the
pressure gauge during
boom up. Do not allow
the pressure to exceed
2500 PSI.
less than 2000 PSI

Check for mechanical

restrictions OR replace
the slave cylinder
counterbalance valves.

Repair or replace the

slave cylinder.

Repair or replace the

master cylinder.

5 - 40

Genie Z-45/22

Part No. 29487

Service Manual - First Edition

Section 5 - Troubleshooting Flow Charts

Chart 26
Platform Level
Up Function
Inoperative
Be sure all other
functions operate
normally.
If platform level up
function operates
normally from the
ground controls but not
from the platform
controls, troubleshoot
the platform control
toggle switch. 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.

Hold ground control

function switch and
check volts at org wire
on platform level up
function directional
valve.
12V

0V

Repair open in org wire

circuit from TB13 to
directional valve.

Remove both wires from

valve coil and check
resistance across the
coil terminals.

0 or infinite ohms

4 to 5 ohms
Hold toggle switch right
and manually override
the level up directional
function operates
valve (push in button on
end of valve spool) OR
inter-change the valve
(item D) with a like valve
(item E).
function inoperative
Install a pressure gauge
at the quick disconnect
coupling on the function
manifold and hold the
function switch.

2000
PSI

less than 2000 PSI

Remove the level up
function pressure line
from the manifold and
cap the port (PL1). Then,
with pressure gauge still
attached, operate the
function up.

2000
PSI

less than 2000 PSI

Interchange the level up

and down
counterbalance valves in
the sandwich block.
function
operates
Replace defective
counterbalance valve.

Repair the master and/or

slave cylinder OR
replace the slave
cylinder counterbalance
valves.

Replace the directional

valve OR the manifold
has internal defects OR
one of the previous tests
was possibly overlooked
or diagnosed incorrectly.
Recheck and/or consult
Genie Industries service
department.

Part No. 29487

Replace the coil.

Genie Z-45/22

Replace the platform

leveling directional
valve.

2000
PSI

Check for mechanical

restrictions and/or a
condition exists in
which the cylinder
counterbalance valves
are not allowing the
cylinder to extend or
the cylinder has
internal defects.
Disconnecting
hydraulic lines or
adjusting the cylinder
counterbalance valves
in this situation can be
very dangerous
Please consult Genie
Industries service
department.

5 - 41

Service Manual - First Edition

Section 5 - Troubleshooting Flow Charts

Chart 27
Platform Level
Down Function
Inoperative
Be sure all other
functions operate
normally.
If platform level down
function operates
normally from the
ground controls but not
from the platform
controls, troubleshoot
the platform control
toggle switch. 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.

Hold ground control

function switch and
check volts at org/blk
wire on platform level
down function directional
valve.
12V

0V

Repair open in org/blk

wire circuit from TB14 to
directional valve.

Remove both wires from

valve coil and check
resistance across the
coil terminals.

0 or infinite ohms

4 to 5 ohms
Hold toggle switch and
manually override the
function operates
level down directional
valve (push in button on
end of valve spool) OR
interchange valve (item
D) with a like valve (item
E).
function inoperative
Install a pressure gauge
at the quick disconnect
coupling on the function
manifold and hold the
function switch.

2000
PSI

less than 2000 PSI

Remove the level down
function pressure line
from the manifold and
cap the port (PL2). Then,
with pressure gauge still
attached, operate the
function down.

2000
PSI

less than 2000 PSI

Interchange the level up

and down
counterbalance valves in
the sandwich block.
function
operates
Replace defective
counterbalance valve.

Repair the master and/or

slave cylinder OR
replace the slave
cylinder counterbalance
valves.

Replace the directional

valve OR the manifold
has internal defects OR
one of the previous tests
was possibly overlooked
or diagnosed incorrectly.
Recheck and/or consult
Genie Industries service
department.

5 - 42

Replace the coil.

Genie Z-45/22

Replace the platform

leveling directional
valve.

2000
PSI

Check for mechanical

restrictions and/or a
condition exists in
which the cylinder
counterbalance valves
are not allowing the
cylinder to retract or
the cylinder has
internal defects.
Disconnecting
hydraulic lines or
adjusting the cylinder
counterbalance valves
in this situation can be
very dangerous
Please consult Genie
Industries service
department.

Part No. 29487

Service Manual - First Edition

Section 5 - Troubleshooting Flow Charts

Chart 28
Platform Rotate
Left Function
Inoperative
Be sure all other
functions operate
normally.
If platform rotate left
function operates
normally from the
ground controls but not
from the platform
controls, troubleshoot
the platform control
toggle switch. 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.

Hold ground control

function switch and
check volts at grn wire
on platform rotate left
function directional
valve.
12V

0V

Repair open in grn wire

circuit from TB16 to
directional valve.

Remove both wires from

valve coil and check
resistance across the
coil terminals.

0 or infinite ohms

Replace the coil.

4 to 5 ohms
Hold toggle switch left
and manually override
the rotate left directional function operates
valve (push in button on
end of valve spool). OR
interchange valve (item
E) with a like valve (item
D).
Interchange the platform
function inoperative rotate left and right
counterbalance valves in
Install a pressure gauge 2000
the manifold installed on
at the quick disconnect
PSI
the primary boom
coupling on the function
extension located under
manifold and hold the
the platform.
function switch.
less than 2000 PSI
Remove the rotate left
function pressure line
from the manifold and
cap the port (PR1).
Then, with pressure
gauge still attached,
operate the function left.

2000
PSI

less than 2000 PSI

function
operates
Replace defective
counterbalance valve.

Replace the platform

rotate directional
valve.

2000
PSI

Check for mechanical

restrictions keeping
platform from rotating
OR repair hydraulic
rotator OR replace
directional valve.

Repair the hydraulic

rotator OR replace the
rotator counterbalance
valves and/or manifold.

Replace the directional

valve OR the manifold
has internal defects OR
one of the previous tests
was possibly overlooked
or diagnosed incorrectly.
Recheck and/or consult
Genie Industries service
department.

Part No. 29487

Genie Z-45/22

5 - 43

Service Manual - First Edition

Section 5 - Troubleshooting Flow Charts

Chart 29
Platform Rotate
Right Function
Inoperative
Be sure all other
functions operate
normally.
If platform rotate right
function operates
normally from the
ground controls but not
from the platform
controls, troubleshoot
the platform control
toggle switch. 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.

Hold ground control

function switch and
check volts at grn/blk
wire on platform rotate
right function directional
valve.
12V

0V

Repair open in grn/blk

wire circuit from TB17 to
directional valve.

Remove both wires from

valve coil and check
resistance across the
coil terminals.

0 or infinite ohms

Replace the coil.

4 to 5 ohms
Hold toggle switch right
and manually override
the rotate right
function operates
directional valve (push in
button on end of valve
spool) OR interchange
valve (item E) with a like
valve (item D).
Interchange the platform
function inoperative rotate left and right
counterbalance valves in
Install a pressure gauge 2000
the manifold installed on
at the quick disconnect
PSI
the primary boom
coupling on the function
extension located under
manifold and hold the
the platform.
function switch.
less than 2000 PSI
Remove the rotate right
function pressure line
from the manifold and
2000
cap the port (PR2).
PSI
Then, with pressure
gauge still attached,
operate the function
right.
less than 2000 PSI

function
operates
Replace defective
counterbalance valve.

Replace the platform

rotate directional
valve.

2000
PSI

Check for mechanical

restrictions keeping
platform from rotating
OR repair hydraulic
rotator OR replace
directional valve.

Repair the hydraulic

rotator OR replace the
rotator counterbalance
valves and/or manifold.

Replace the directional

valve OR the manifold
has internal defects OR
one of the previous tests
was possibly overlooked
or diagnosed incorrectly.
Recheck and/or consult
Genie Industries service
department.

5 - 44

Genie Z-45/22

Part No. 29487

Service Manual - First Edition

Section 5 - Troubleshooting Flow Charts

Chart 30
Oscillate
Lock-out
Function
Inoperative

wedges
Raise the primary boom
until it is above the drive extend
limit switch and measure 3
inches
the oscillate lock-out
wedges. See
Maintenance Procedures
B-17.
wedges do not
extend 3 inches

Check voltage at blk #56

on CR6.

12V

0V

Check CR7 green

grounding wire OR
replace CR7 relay or
socket.

12V

Drive limit switch

shorted, repair or
replace.

12V

Replace CR6 relay or

relay socket.

0V
Check voltage at blk #55
on oscillate valve.

Check voltage at blk #57

wire on CR7.

Open in wht wire (12V

supply) to oscillate
limit switches OR one
or both oscillate limit
switches is defective.

0V
Remove machine from
service and please
consult Genie Industries
service department.

Part No. 29487

Genie Z-45/22

5 - 45

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.

Start the engine from the

platform, press down
foot switch, hold the
steer switch left and
check volt-age at
terminal 8 on the drive
controller (blu wire).
12V

0V

Repair or replace the

steer microswitch in
controller handle.

Hold the steer switch left

and check voltage at
TB31.

0V

Repair open in blu wire

circuit from TP43 to
TB31.

0V

Repair open in blk #31

wire circuit from TB31 to
steer valve.

12V
Hold the steer switch left
and check voltage at blk
#31 wire on steer valve.
12V
Remove both wires from
steer left coil and check
resistance across coil
terminals.

0 or infinite ohms

Replace steer left valve

coil.

4 to 8 ohms
Reconnect coil wires,
hold steer switch and
check voltage at steer
unload valve.
12V

0V

Test and replace diode

or repair open in jumper
wire circuit from steer left
coil to steer unload
valve.

Replace steer valve.

5 - 46

Genie Z-45/22

Part No. 29487

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.

0V

Repair or replace the

steer microswitch in
controller handle.

0V

Repair open in blu wire

circuit from TP44 to
TB32.

Hold the steer switch

right and check voltage
at blk #32 wire on steer
valve.
12V

0V

Repair open in blk #32

wire circuit from TB32 to
steer valve.

Remove both wires from

steer right coil and check
resistance across coil
terminals.

0 or infinite ohms

Start the engine from the

platform, press down
foot switch, hold the
steer switch right and
check volt-age at
terminal 7 on the drive
controller (blu/blk wire).
12V
Hold the steer switch left
and check voltage at
TB32.
12V

Replace steer right valve

coil.

4 to 8 ohms
Reconnect coil wires,
hold steer switch and
check voltage at steer
unload valve.
12V

0V

Test and replace diode

or repair open in jumper
wire circuit from steer
right coil to steer unload
valve.

Replace steer valve.

Part No. 29487

Genie Z-45/22

5 - 47

Service Manual - First Edition

Section 5 - Troubleshooting Flow Charts

Chart 33
All Drive
Functions
Inoperative,
All Other
Functions
Operate
Normally
Be sure the hydraulic
suction line valve is in
the open position.

Start engine from ground

controls and standing
clear of the tires,
momentarily move pump
control override lever in
each direction.

machine does not move

Repair or replace the

drive pump.

machine moves
Move to platform, press
down foot switch, hold
drive enable switch to
either side and try to
drive.
no drive

Place a jumper wire

machine between TB38 and TB26
drives
and test drive without
holding drive enable
switch.

machine Repair open in wht

drives
wire circuit from TP37
to TB38.

no drive

Be sure machine is not

in the free wheel
configuration.

Replace drive enable

limit switch OR repair
open in blk #38 or blk
#59 wires from terminals
TB38 and TB26 to limit
switch.

Disconnect drive pump

electronic displacement
0 or infinite ohms
controller (EDC) wires
and check resistance
across both wires on
EDC side of quick
disconnect.
20 to 24 ohms
Press down foot switch
and check voltage at
horsepower limiter board
terminal 1.

Replace EDC.

Correct insufficient
voltage supply OR
repair open in wht wire
circuit supplying 12V
to terminal 1.

less than 12V

12V or more
Switch rpm select switch
to rabbit with foot switch,
press down foot switch
and check voltage at
terminal 3 on
horsepower limiter.
6 to 7V
Continued on the next
page.

5 - 48

0V

Check voltage at TB40.

6 to 7V

Repair open in org/blk

wire circuit from TB40
to horsepower limiter
terminal 3.

0V
Check voltage at blk #40
wire on engine
alternator.
0V

6 to 7V

Repair open in blk #40

wire circuit from
alternator to TB40.

Repair or replace
alternator.

Genie Z-45/22

Part No. 29487

Service Manual - First Edition

Section 5 - Troubleshooting Flow Charts

CHART 33

Continued from the

previous page.

Press down foot switch

and check voltage at
terminal 10 on
horsepower limiter.

0V

Replace horsepower
limiter board.

0V

Repair open in red wire

circuit from horsepower
limiter through TP15 to
drive mode switch.

0V

Repair open in red wire

circuit from drive mode
switch to drive controller.

9 to 12V
Press down foot switch
and check voltage at red
wire on center terminal
of drive mode select
switch.
9 to 12V
Switch drive mode to
high range (two wheels),
press down foot switch
and check voltage at
terminal 6 on drive
controller.
9 to 12V
Disconnect drive pump
EDC wires, press down
foot switch, hold drive
controller in full forward
position and check
voltage across terminals
4 and 5 on drive
controller.
4 to 5V
Press down foot switch,
hold drive controller in
full forward position and
check voltage across
terminals TP37 and
TP38.
4 to 5V
Press down foot switch,
hold drive controller in
full forward position and
check voltage across
terminals TB26 and
TB27.
4 to 5V
Press down foot switch,
hold drive controller in
full forward position,
check voltage across
two wires at EDC quick
disconnect.

Part No. 29487

0V

0V

0V

0V

4 to 5V

Replace drive controller.

Repair open in either wht

or wht/blk wire circuit
from drive controller to
TP38 and TP38
respectively.

Repair open in wht/blk

wire circuit from TP38 to
TB27.
Repair open in either blk
#27 or blk #26 circuits
from TB27 and TB26 to
EDC.
Replace drive pump
EDC.

Genie Z-45/22

5 - 49

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.

Disconnect the EDC wire

connector from the drive
pump , start engine,
move the drive controller
to full forward position
and note the voltage
across terminals TB27
and TB26. Reverse the
volt meter leads and
move the drive controller
to full reverse position
and note the voltage.

voltage readings are different

Repair or replace the

drive controller.

voltage readings are the same

Adjust the drive pump
no improvement
null (neutral). See
Sundstrand Series 40
Service Manual.
symptoms improve

Defective Sundstrand
drive pump, contact
Sundstrand authorized
repair facility

Check all drive speeds

and monitor for recurring
symptoms. Possible
contamination in
hydraulic system.

5 - 50

Genie Z-45/22

Part No. 29487

Service Manual - First Edition

Section 5 - Troubleshooting Flow Charts

Chart 35
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.

Start engine from

platform controls, switch
drive mode to high and
press down the foot
switch. Check the
voltage at terminal TB21.

0V

Continued on the next

page.

12V
Press down foot switch,
wait 3 seconds and
check voltage at blk #21
wire on the motor stroke
solenoid valve (item N).

0V

Repair open in blk #21

wire circuit from TP21 to
stroke solenoid valve.

0V

Repair open in blk #21

wire circuit from TP21 to
time delay relay.

0V

Check voltage at wht

wire on terminal 1 of time
delay relay.

12V
Press down foot switch,
wait 3 seconds and
check voltage at blk #21
wire on terminal 6 of time
delay relay.
12V
Press down foot switch,
wait 3 seconds and
check voltage at blk #41
wire on terminal 3 of time
delay relay.

0V

Repair open in wht

wire circuit from
supplying 12V to time
delay relay.

no high
drive

Consult Genie
Industries service
department.

12V
Replace time delay
relay.

12V
Press down foot switch,
wait 3 seconds and
check voltage at blk #41
wire on traction bypass
solenoid valve (item Q).

0V

Repair open in blk #41

wire circuit from time
delay relay to traction
bypass valve.

12V
Interchange traction
bypass valve (item Q)
with new solenoid valve
and check high drive.
no high drive
Replace traction bypass
and interchange new
valve with motor stroke
valve (item R) and check
high drive.

Part No. 29487

no high
drive

Replace traction bypass

shuttle valve and check
high drive.

Genie Z-45/22

5 - 51

Service Manual - First Edition

Section 5 - Troubleshooting Flow Charts

CHART 35

Continued from the

previous page.

Press down foot switch

and check voltage at
TP27.

12V

Repair open in red/wht

wire circuit from TP27 to
TB21.

12V

Repair open in red/wht

wire circuit from toggle
switch to TP27.

0V
Press down foot switch
and check voltage at
red/wht wire on drive
mode select switch.
0V
Press down foot switch
and check voltage at wht
wire supplying 12V to
drive mode select
switch.
0V

12V

Replace toggle switch.

Repair open in wht wire

circuit supplying 12V to
toggle switch.

5 - 52

Genie Z-45/22

Part No. 29487

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).

Turn key switch to

platform controls, pull
both emergency stop
buttons on, switch drive
mode to low range (four
wheel symbol), press
down foot switch and
check voltage at red/wht
wire on drive mode
switch.
0V

12V

Replace drive mode

toggle switch.

Press down foot switch

and check voltage at
TB21.

12V

Repair short in red/wht

wire circuit from drive
mode switch through
TP27 to TB21.

12V

Replace TR3 time delay

relay.

0V
Press down foot switch
and check voltage at blk
#41 on traction bypass
valve (item Q).
0V
Interchange bypass
valve (item Q) with brake
release valve (item S).

low range operates

Replace defective valve.

low range inoperative

Interchange motor shift
valve (item R) with brake
release valve (item S).

low range operates

Replace defective valve.

low range inoperative

Check drive mode toggle
switch. See Repair
section.

bad

Replace toggle switch.

OK
Check drive resisters in
platform control box. See
repair section.

bad

Replace defective
resister(s).

OK
Possible defective drive
manifold or drive
manifold component.
Please consult Genie
Industries service
department.

Part No. 29487

Genie Z-45/22

5 - 53

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.

With boom fully stowed,

check TB37 for
continuity to ground.

full continuity

Repair or replace drive

limit switch.

no continuity
With boom fully stowed,
check horsepower limiter
board terminal 6 for
continuity to ground.

full continuity

no continuity

Orange wire shorted to

ground, repair orange
wire circuit from TB37 to
horsepower limiter
board.

Re-adjust horsepower
limiter board. See Repair
section.

5 - 54

Genie Z-45/22

Part No. 29487

Service Manual - First Edition

Section 6 - Troubleshooting Flow Charts

Schematics
About This Section
There are two groups of schematics in this
section. An illustration legend precedes each
group of drawings.
Electrical Schematics
Electrocution hazard. Contact with
hot or live circuits may result in
death or serious injury. Remove
all rings, watches and other
jewelry.

Observe and Obey:

Troubleshooting and repair procedures shall be
completed by a person trained and qualified on
the repair of this machine.
Immediately tag and remove from service a
damaged or malfunctioning machine.

Hydraulic Schematics
Bodily injury hazard. Spraying
hydraulic oil can perforate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.

Repair any machine damage or malfunction

before operating the machine.

Before Troubleshooting:
Read, understand and obey the safety rules
and operating instructions printed in the Genie
Z-45/22 Operating Instruction Manual.
Be sure that all necessary tools and test
equipment are available and ready for use.

General Repair Process

Malfunction
discovered

Identify
symptoms

Troubleshoot

problem
still exists

Return to
service

Part No. 29487

Genie Z-45/22

problem
solved

Inspect
and test

Perform
repair

6-1

Service Manual - First Edition

Section 6 - Troubleshooting Flow Charts

Electrical Symbol Legend

TB17

BLK

ORG/BLK-1

GRN/BLK

Circuit breaker

Water temperature
switch
normally closed

Wire color
with cable
number

Solenoid or
relay coil

Ground
supression
circuit

Starter motor
relay

WHT #51

TB20

PR5

WTS1 N.O.

15AMP.

FS1
BLK

RED

TR2

1
2

Foot switch

Terminal

Time delay relay

TILT
ALARM

TP29

LS4
NC

NO
1

Quick disconnect
terminal

Horn

Limit switch

KS1

GRND
BLK #21

Key switch

TB21

T-circuits connect
at terminal

PLAT

TR1

Time delay relay

LS1
NO

L4 OP

TS3

Light

HORN

ENGINE
START

Limit switch
normally open
held closed

P4

Toggle switch SPDI

T-circuits
connect
10

Horn button
normally open

Resistor

TS6

LS2
NC

Limit switch
normally closed
held open

RIGHT

LEFT

Connection
no terminal

P1

Toggle switch DPDT

Emergency Stop
button
normally closed

BP2
PWM
A
+

Circuits crossing
no connection

Tilt sensor

VAC

CR4

Vacuum switch
Diode

Single axis
proportional
controller

Relay contact
normally open

Spark plug

BP1

OPS1 N.C.

+
-

Battery

6-2

Glow plug

Oil pressure
switch
normally closed

Genie Z-45/22

PWM
PR4

Relay panel
contactor

PWM

Dual axis
proportional
controller

Part No. 29487

6-3

6-5

6-6

6-7

6-8

6-10

6-11

6-12

Service Manual - First Edition

Section 6 - Troubleshooting Flow Charts

Hydraulic Symbol Legend

Cylinder

Solenoid operated 2 pos.,

4 way, directional valve

Pressure gauge
Differential
sensing valve

Accumulator
Filter

Solenoid operated 3 pos.,

4 way, directional valve (DO1)
0.035

Orifice with size

Solenoid operated
proportional valve
2 pos., 3 way, shuttle valve

Fixed displacement
pump

Variable orifice
or shut-off valve

Flow regulator valve

Bi-directional,
variable
displacement pump

Check valve

Relief valve

3 pos., 4 way, directional valve

Solenoid operated 2 pos.,

3 way, directional valve
Sequencing valve

Bi-directional motor

Priority
flow divider
2-speed,
bi-directional motor

Pump prime mover

(engine or motor)

Part No. 29487

Solenoid operated
dump valve

Counterbalance valve

Genie Z-45/22

6-3

Z45-22 Hyd. Index

Z45-22 Hyd. Index

Z45-22 Hyd. Index

Z45-22 Hyd. Index

Z45-22 Hyd. Index

Z45-22 Hyd. Index

Service Manual - First Edition

Section 7 - Repair Procedures

Repair Procedures
About This Section
Most of the procedures in this section should only
be performed by a trained service professional in a
suitably equipped workshop. Select the
appropriate repair procedure after troubleshooting
the problem.

Observe and Obey:

Repair procedures shall be completed by a
person trained and qualified on the repair of
this machine.
Immediately tag and remove from service a
damaged or malfunctioning machine.
Repair any machine damage or malfunction
before operating the machine.

Perform disassembly procedures to the point

where repairs can be completed. Then to reassemble, perform the disassembly steps in
reverse order.
General Repair Process

Malfunction
discovered

Before Repairs Start:

Read, understand and obey the safety rules
and operating instructions printed in the Genie
Z-45/22 Operating Instruction Manual.
Be sure that all necessary tools and parts are
available and ready for use.

Identify
symptoms

Troubleshoot

problem
still exists

Return to
service

problem
solved

Inspect
and test

Perform
repair

Symbols Legend

Read each procedure thoroughly. Attempting

shortcuts may produce hazardous conditions.

Indicates the presence of a

hazard that will cause death or
serious injury.
Indicates the presence of a
hazard that may cause death or
serious injury.
Indicates the presence of a
hazard that will or may cause
serious injury or damage to the
machine.
Indicates special operation or
maintenance information.
Indicates that a specific result is expected after
performing a series of steps.

Part No. 29487

Genie Z-45/22

7-1

Service Manual - First Edition

Section 7 - Repair Procedures

Platform Controls
1-1
Joystick Controllers

Maintaining each joystick controller at the proper

settings is essential to safe machine operation.
Every joystick controller should operate smoothly
and provide proportional speed control over its
entire range of motion.
a

a
b
c
d
e
f
g
h
i
j

f
a
b
c
d
e
f
g

dual (lo) adjustable trimpot

ramp rate adjustable trimpot
terminal "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

4 Set the ramp rate: Turn the trimpot adjustment

screw clockwise 15 turns or until you hear a
click, then turn the screw counterclockwise 5
turns.

horsepower limiter
quick disconnect terminal strip
drive proportional controller
primary boom proportional controller
turntable rotate proportional controller
extend/retract proportional controller
secondary boom proportional
controller

Primary Boom Up/Down

Controller Adjustments
1 Check the battery condition with a volt meter.
The reading should be 12V DC or more to
accurately adjust the controller.
2 Turn the key switch to platform control and pull
the Emergency Stop button to the on position
at both the ground and platform controls. Do
not start the engine.

5 Connect the red lead(+) from a volt meter to

the A terminal on the controller PC board.
Connect the black lead(-) to ground.
6 Set the threshold: Press down the foot switch,
then slowly move the control handle off center
until the moment a voltage reading appears.
Adjust the voltage to 2.50V DC. Turn the
threshold trimpot adjustment screw clockwise
to increase the voltage or counterclockwise to
decrease the voltage.
7 Set the max-out: Press down the foot switch,
then move the control handle all the way to the
up position. Adjust the voltage to 5.02V DC.
Turn the max-out trimpot adjustment screw
clockwise to increase the voltage or
counterclockwise to decrease the voltage.

3 Open the platform control box lid and locate the

primary up/down controller.

7-2

Genie Z-45/22

Part No. 29487

Service Manual - First Edition

Section 7 - Repair Procedures

PLATFORM CONTROLS

8 Set the dual (lo) range: Press down the foot

switch, then move the control handle all the
way to the down position. Adjust the voltage to
4.33V DC. Turn the dual range trimpot
adjustment screw clockwise to increase the
voltage or counterclockwise to decrease the
voltage.
7 Start the engine and move the engine speed
control switch to foot switch activated high idle
(rabbit and foot switch symbol). Raise the
primary boom 1 inch (2.5cm) above the drive
limit switch.
Engine should be at normal
operating temperature.

Primary Boom Extend/Retract

Controller Adjustments
1 Check the battery condition with a volt meter.
The reading should be 12V DC or more to
accurately adjust the controller.
2 Turn the key switch to platform control and pull
the Emergency Stop button to the on position
at both the ground and platform controls. Do
not start the engine.
3 Open the platform control box lid and locate the
primary extend/retract controller.
a

8 Start a timer and record how long it takes for

the primary boom to reach the full up position.
Adjust the max-out trimpot to achieve a 25 to
29 second cycle time.
9 Start a timer and record how long it takes for
the primary boom to lower into the full down
position. Adjust the dual range trimpot to
achieve a 33 to 37 second cycle time.
Specifications - Primary Boom Up/Down Function
Threshold

2.50V DC

Primary boom up Max-out time

5.02V DC
25-29 seconds

Primary boom down Dual range time

4.33V DC
33-37 seconds

a
b
c
d
e
f
g
h
i
j

dual (lo) adjustable trimpot

ramp rate adjustable trimpot
terminal "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

4 Set the ramp rate: Turn the trimpot adjustment

screw clockwise 15 turns or until you hear a
click, then turn the screw counterclockwise 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

Service Manual - First Edition

Section 7 - Repair Procedures

PLATFORM CONTROLS

6 Set the threshold: Press down the foot switch,

then slowly move the control handle off center
until the moment a voltage reading appears.
Adjust the voltage to 2.94V DC. Turn the
threshold trimpot adjustment screw clockwise
to increase the voltage or counterclockwise to
decrease the voltage.
7 Set the max-out: Press down the foot switch,
then move the control handle all the way to the
extend position. Adjust the voltage to
7.00V DC. Turn the max-out trimpot
adjustment screw clockwise to increase the
voltage or counterclockwise to decrease the
voltage.
8 Set the dual (lo) range: Press down the foot
switch then move the control handle all the way
to the retract position. Adjust the voltage to
7.00V DC. Turn the dual range trimpot
adjustment screw clockwise to increase the
voltage or counterclockwise to decrease the
voltage.

Specifications - Primary Boom Extend/Retract

Function
Threshold

2.50V DC

Primary boom extend Max-out time

5.01V DC
23-27 seconds

Primary boom retract Dual Range time

4.05V DC
23-27 seconds

Secondary Boom Up/Down

Controller Adjustments
1 Check the battery condition with a volt meter.
The reading should be 12V DC or more to
accurately adjust the controller.
2 Turn the keyswitch to platform control and pull
the Emergency Stop button to the on position
at both the ground and platform controls. Do
not start the engine.
3 Open the platform control box lid and locate the
secondary boom up/down controller.

Engine should be at normal

operating temperature.
9 Start the engine and move the engine speed
control switch to foot switch activated high idle
(rabbit and foot switch symbol). Raise the
primary boom until it is level. Fully retract the
primary boom.

10 Start a timer and record how long it takes for

the primary boom to reach full extension.
Adjust the max-out trimpot to achieve a 29 to
33 second cycle time.
11 Start a timer and record how long it takes for
the primary boom to fully retract. Adjust the
dual range trimpot to achieve a 22 to 26
second cycle time.

7-4

Genie Z-45/22

a
b
c
d
e
f
g
h
i
j

dual (lo) adjustable trimpot

ramp rate adjustable trimpot
terminal "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

Part No. 29487

Service Manual - First Edition

Section 7 - Repair Procedures

PLATFORM CONTROLS

4 Set the ramp rate: Turn the trimpot adjustment

screw clockwise 15 turns or until you hear a
click, then turn the screw counterclockwise
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.
6 Set the threshold: Press down the foot switch,
then slowly move the control handle off center
until the moment a voltage reading appears.
Adjust the voltage to 2.50V DC. Turn the
threshold trimpot adjustment screw clockwise
to increase the voltage or counterclockwise to
decrease the voltage.
7 Set the max-out: Press down the foot switch,
then move the control handle all the way to the
up position. Adjust the voltage to 5.01V DC.
Turn the max-out trimpot adjustment screw
clockwise to increase the voltage or
counterclockwise to decrease the voltage.
8 Set the dual range: Press down the foot switch,
then move the control handle all the way to the
down position. Adjust the voltage to 4.05V DC.
Turn the dual range trimpot adjustment screw
clockwise to increase the voltage or
counterclockwise to decrease the voltage.

Specifications - Secondary Boom Up/Down

Function
Threshold

2.94V DC

Secondary boom up Max-out time

7.00V DC
29-33 seconds

Secondary boom down Dual Range time

7.00V DC
22-26 seconds

Turntable Rotation Controller

Adjustments
1 Check the battery condition with a volt meter.
The reading should be 12V DC or more to
accurately adjust the controller.
2 Turn the key switch to platform control and pull
the Emergency Stop button to the on position
at both the ground and platform controls. Do
not start the engine.
3 Open the platform control box lid and locate the
secondary boom up/down controller.
a

Engine should be at normal

operating temperature.
9 Start the engine and move the engine speed
control switch to foot switch activated high idle
(rabbit and foot switch symbol). Raise the
primary boom 1 inch (2.5cm) above the drive
limit switch.
10 Start a timer and record how long it takes for
the secondary boom to reach the full up
position. Adjust the max-out trimpot to achieve
a 23 to 27 second cycle time.
11 Start a timer and record how long it takes for
the secondary boom to lower into the full down
position. Adjust the dual range trimpot to
achieve a 23 to 27 second cycle time.

Part No. 29487

Genie Z-45/22

a
b
c
d
e
f
g
h
i
j

dual (lo) adjustable trimpot

ramp rate adjustable trimpot
terminal "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

7-5

Service Manual - First Edition

Section 7 - Repair Procedures

PLATFORM CONTROLS

4 Set the ramp rate: Turn the trimpot adjustment

screw clockwise 15 turns or until you hear a
click, then turn the screw counterclockwise
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.
6 Set the threshold: Press down the foot switch
then slowly move the control handle off center
until the moment a voltage reading appears.
Adjust the voltage to 3.35V DC. Turn the
threshold trimpot adjustment screw clockwise
to increase the voltage or counterclockwise to
decrease the voltage.
7 Set the max-out: Press down the foot switch
then move the control handle all the way to the
full right or full left position. Adjust the voltage
to 6.26V DC. Turn the max-out trimpot
adjustment screw clockwise to increase the
voltage or counterclockwise to decrease the
voltage.

1-2
Horsepower Limiter Board
The horsepower limiter board is responsible for
governing drive pump output. It reads engine rpm
from the alternator. The horsepower limiter board
senses drops in rpm normally due to increased
drive resistance (rough terrain or incline) and
decreases voltage to the drive controller which in
turn decreases voltage to the drive pump thereby
reducing pump output to keep the engine from
stalling. Three adjustments are required for
optimum performance.

How to Adjust the Horsepower

Limiter Board
a

8 Set the dual (lo) range: Turn the trimpot

adjustment screw clockwise 15 turns or until
you hear a click. This is the only dual range
adjustment for this controller.
Engine should be at normal
operating temperature.
6 Start the engine and move the engine speed
control switch to foot switch activated high idle
(rabbit and foot switch symbol). Rotate the
turntable to the full right position.
7 Start a timer and record how long it takes the
turntable to rotate to the full left position. Adjust
the max-out trimpot to achieve a
71 to 75 second cycle time.

horsepower limiter board

1 Remove the fasteners from the platform control

box lid.
2 Open the control box lid and locate the
horsepower limiter board.

Specifications - Turntable Rotation function

Threshold

3.35V DC

Turntable rotation Max-out time

6.26V DC
71-75 seconds

7-6

Genie Z-45/22

Part No. 29487

Service Manual - First Edition

Section 7 - Repair Procedures

PLATFORM CONTROLS

a
12V DC or greater
ground
engine rpm sensor
not used
not used
low drive speed limit switch
not used
not used
not used
output to drive controller

8 Press down the foot switch and then adjust the

"C" potentiometer to obtain a 0.01V DC to
0.03V DC voltage reading.
9 Move the engine speed control switch to foot
switch activated high idle (rabbit and foot
switch symbol).

Horsepower limiter board

a
"A" potentiometer-maximum voltage
output to the controller in the stowed
position
b
"B" potentiometer-maximum voltage
output to the drive controller in the
boom elevated position
c
"C" potentiometer-reaction rate or
how fast the voltage output reacts to
the change in engine rpm

10 Press down the foot switch and re-adjust the

"A" potentiometer to the previous voltage
setting
11 Be sure that the boom is in the fully stowed
position, then drive the boom and observe how
the engine rpm reacts to drive control handle
movement. If the machine surges or hunts,
adjust the "C" potentiometer counterclockwise
until surging is minimized..
Under an extreme load, an
excessive counterclockwise
adjustment to the "C"
potentiometer will cause the
engine to stall. The "C"
potentiometer adjustment is a
compromise between engine
stability and engine droop.

Electrocution hazard. Contact with

hot or live circuits may result in
death or serious injury. Remove
all rings, watches and other
jewelry.
3 Connect the black lead(-) from a DC volt meter
to the number 2 terminal, and the red lead(+) to
the number 10 terminal.
4 Start the engine from the platform controls.

12 Disconnect the volt meter.

13 Raise the primary boom above the drive limit
switch.

5 Move the engine speed control switch to foot

switch activated high idle (rabbit and foot
switch symbol).
6 Press down the foot switch and adjust the "A"
potentiometer counterclockwise to increase
voltage or clockwise to decrease voltage.
a

Specifications - "A" Pot Setting

Voltage setting - 2WD model

8.0V DC

Voltage setting - 4WD model

9.0V DC

7 Move the engine speed control switch to low

idle (turtle symbol).

Part No. 29487

drive limit switch

14 Drive the boom for 20 feet (6.1m) and record

the elapsed time. Do this again in the opposite
direction.

Genie Z-45/22

7-7

Service Manual - First Edition

Section 7 - Repair Procedures

PLATFORM CONTROLS

15 Adjust the "B" potentiometer to obtain the

correct elevated drive speed of 1 foot per
second (30.5cm per second).

Do not use the colors of the

connector as a guide for these
tests. Use the actual wire color to
identify which contact to use for
testing.

16 Close the platform control box lid and re-install

the fasteners.
Specifications
Stowed position, high range, distance: 20 ft / 6m
2WD

2.85 seconds (0.25 seconds)

4WD

2.75 seconds (0.25 seconds)

Boom raised, high range, distance: 20 ft / 6m

2WD and 4WD

1 foot per second /

30.5cm per second

3 Press down the foot switch. Connect the leads

from an ohmmeter or continuity tester to each
wire connector combination listed below and
check for continuity.
Test

Desired result

red to black

no continuity (infinite )

red to white

no continuity

black to white

continuity (zero )

1-3
Foot Switch

1-4
Resistors

How to Test the Foot Switch

Two resistors are used to maintain proper control

of drive speeds. Both resistors are located in the
platform control box.

1 Turn the keyswitch to the off position and

disconnect the wiring quick disconnect plug
from the platform toe board.
2 Do not press down the foot switch. Connect the
leads from an ohmmeter or continuity tester to
each wire connector combination listed below
and check for continuity.
Test

Desired result

red to black

continuity (zero )

red to white

no continuity (infinite )

black to white

no continuity

7-8

How to Test the Resistors

1 Turn the keyswitch to the off position and set
the drive mode select switch to high range
(two-wheel symbol).
2 Connect the leads from an ohmmeter to each
end of the resistor being tested.
3 Compare the ohmmeter reading with the
resistance rating printed on the resistor.

Genie Z-45/22

Part No. 29487

Service Manual - First Edition

Section 7 - Repair Procedures

PLATFORM CONTROLS

1-5
Toggle Switches

Test

Toggle switches used for single function switching

are single pole double throw (SPDT) switches.
Two function switching requires a double pole
double throw (DPDT) switch.

terminal 1 to 2, 3, 4, 5, & 6

no continuity (infinite )

terminal 2 to 3

continuity (zero )

terminal 2 to 4, 5 & 6

no continuity

How to Test a Toggle Switch

terminal 3 to 4, 5 & 6

no continuity

This procedure covers fundamental switch testing

and does not specifically apply to all varieties of
toggle switches.

terminal 4 to 5 & 6

no continuity

terminal 5 to 6

continuity

Center position

There are no terminal

combinations that will
produce continuity
(infinite )

Left Position

1 Turn the keyswitch to the off position and

disconnect all wiring from the toggle switch to
be tested.
2 Connect the leads of an ohmmeter to the
switch terminals in the following combinations
listed below to check for continuity.
Left

Single pole,
double throw
(SPDT)

Right

Center

Desired result

Right Position
terminal 1 to 2

continuity

terminal 1 to 3, 4, 5 & 6

no continuity

terminal 2 to 3, 4, 5 & 6

no continuity

terminal 3 to 4, 5 & 6

no continuity

terminal 4 to 5

continuity

terminal 4 to 6

no continuity

terminal 5 to 6

no continuity

Double pole,
double throw
(DPDT)

Part No. 29487

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Section 7 - Repair Procedures

Platform Components
2-1
Platform

2-2
Platform Leveling Slave Cylinder

How to Remove the Platform

The slave cylinder and the rotator pivot are the

two primary supports for the platform. The slave
cylinder keeps the platform level through the entire
range of primary boom motion. It operates in a
closed-circuit hydraulic loop with the master
cylinder. The slave cylinder is equipped with
counterbalance valves to prevent movement in the
event of a hydraulic line failure.

1 Remove the cable harness from the cable

clamps located under the platform and
disconnect the foot switch wiring plug.
2 Remove the platform control box mounting
bolts, then lift it out and set it aside.
3 Tilt the platform with the ground controls
manual platform leveling switch until the
platform lays horizontal.

How to Remove the Slave

Cylinder
Before cylinder removal is
considered, bleed the slave
cylinder to be sure there is no air
in the closed loop.
1 Tilt the platform with the ground controls
platform leveling switch until the platform is
horizontal.

a
a

b
a
b

2 Place blocks under the platform railing for

support. Then carefully rest the platform on the
blocks.

platform mounting bolts

block

4 Place blocks under the platform railing for

support. Then carefully rest the platform on the
blocks.

3 Disconnect the hydraulic hoses from the slave

cylinder and connect them together with a
straight line connector.
Bodily injury hazard. Spraying
hydraulic oil can perforate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.

5 Remove the platform mounting bolts and

remove the platform.

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

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Part No. 29487

Service Manual - First Edition

Section 7 - Repair Procedures

PLATFORM COMPONENTS

How to Bleed the Slave Cylinder

Do not start the engine. Use
auxiliary power for all machine
functions in this procedure.
1 Raise the primary boom 6 inches (15cm) above
the primary boom rest.
2 Move the manual platform level switch to the
right until the slave cylinder is fully extended.
Continue to hold the platform level switch for
10 seconds.
3 Connect a clear hose to the bleed valve on the
cylinder barrel. Place the other end of the hose
in a container to collect any discharge.

2-3
Platform Rotator
The platform rotator is a hydraulically activated
helical gear assembly used to rotate the platform
180 degrees. It is equipped with external
counterbalance valves to hold platform in place
and to provide pressure relief.

How to Remove the Platform

Rotator
1 Remove the platform. See 2-1, How to Remove
the Platform.
2 Disconnect the hydraulic hoses from the
platform rotator and cap them.
Bodily injury hazard. Spraying
hydraulic oil can perforate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.
3 Remove the 6 mounting bolts from the platform
pivot weldment.

4 Open the bleed valve, but do not remove it.

5 Hold the platform level switch to the right for 5
seconds, then release it.
6 Close the bleed valve, then remove the hoses.
7 Hold the platform level switch to the left until
the slave cylinder is fully retracted.
8 Connect the clear hose to the bleed valve on
the slave cylinder block.

4 Remove the top nut from the threaded rod.

Then pull the rod out the bottom of the platform
rotator and remove the platform pivot
weldment.
5 Support the platform rotator, but do not apply
any lifting pressure.
6 Remove the pin retainer from the slave cylinder
rod-end pivot pin and the rotator pivot pin.
7 Use a soft metal drift to drive the pins out, then
remove the 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.

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Service Manual - First Edition

Section 7 - Repair Procedures

PLATFORM COMPONENTS

How to Bleed the Platform Rotator

holding the platform rotate switch until air stops

coming out of the bleed valve.

1 Connect a clear hose to the top bleed valve.

Place the other end of the hose in a container
to collect any discharge.

Crushing hazard. Keep hands

clear of the platform pivot
weldment during rotation.
10 Close the bleed valve and remove the hose.
11 Turn off the engine and clean up any hydraulic
oil that may have spilled.

a
b

12 Restart the engine from the ground controls.

Then rotate the platform full left and right and
inspect the bleed valves for leaks.

a
b
c
d

clear hose
top bleed valve
bottom bleed valve
container

2 Open the top bleed valve, but do not remove it.

3 Start the engine from the ground controls.
4 Hold the platform rotate switch to the right for
approximately 5 seconds, then release it.
Repeat 3 times.
Crushing hazard. Keep hands
clear of the platform pivot
weldment during rotation.
5 Hold the platform rotate switch to the left for
approximately 5 seconds, then release it.
6 Fully rotate the platform to the left and continue
holding the platform rotate switch until air stops
coming out of the bleed valve. Immediately
release the platform rotate switch and close the
bleed valve.
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

Service Manual - First Edition

Section 7 - Repair Procedures

Primary Boom Components

3-1
Plastic Cable Track

3-2
Primary Boom

The primary boom cable track guides cables and

hoses running up the boom. It can be repaired link
by link without removing the cables and hoses that
run through it. Removing the entire primary boom
cable track is only necessary when performing
major repairs that involve removing the primary
boom.

How to Shim the Primary Boom

Wear Pads

How to Repair the Plastic Cable

Track
Component damage hazard. The
primary boom cable track can be
damaged if it is twisted.

Measure each wear pad. Replace

the pad if it is less than
0.41 inches (1cm) thick. If the pad
is more than 0.41 inches (1cm)
thick, perform the following
procedure.
1 Raise the primary boom above the drive limit
switch.

a
a
b

a
b

drive limit switch

2 Extend the primary boom 10 inches

(25.4cm).

link separation point

lower clip

3 Remove the wear pad mounting fasteners.

1 Use a slotted screwdriver to pry down on the

lower clip.

4 Install the new shims under the wear pad to

obtain zero clearance and zero drag.

2 Repeat step 2 for each link.

5 Using a round punch, align the holes in the

shim to the wear pad and install the mounting
fasteners.

3 To remove a single link, open the lower clip and

then use a screw driver to pry the link to the
side.

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

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Service Manual - First Edition

Section 7 - Repair Procedures

PRIMARY BOOM COMPONENTS

Component damage hazard. The

primary boom cable track can be
damaged if it is twisted.

How to Remove the Primary

Boom
This procedure requires specific
repair skills, lifting equipment and
a suitable workshop. Attempting
this procedure without these skills
and tools may result in death or
serious injury and significant
component damage. Dealer
service is strongly recommended.

5 Raise the secondary boom and place a

4x4x31 inch (78cm) block between the chassis
counterweight and upper mid-pivot. Carefully
lower the secondary boom onto the block.
a

1 Remove the platform. See 2-1, How to Remove

the Platform.

2 Disconnect and plug the hydraulic hoses at the

slave cylinder and the platform rotator
counterbalance valve.
Bodily injury hazard. Spraying
hydraulic oil can perforate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.
3 Remove the fasteners that secure the upper
cable track tray to the primary boom.
4 Loosen the fasteners that secure the lower
cable track tray. Tie the upper and lower cable
tracks together with wire ties. Remove the
cable track assembly from the primary boom.
a

b
a
b
c

7 - 14

a
b
c

Crushing hazard. Keep hands

away from the block and all
moving parts when lowering the
secondary boom.
6 Raise the end of the primary boom 8 feet
(2.5m) off the ground, then extend the primary
boom 5 inches (12.5cm).
7 Attach an overhead crane to the primary boom.
Do not lift the primary boom.
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.

upper mid-pivot
4x4x31 inch block
counterweight

wood block
tie-wrap
plastic cable track

Genie Z-45/22

Part No. 29487

Service Manual - First Edition

Section 7 - Repair Procedures

PRIMARY BOOM COMPONENTS

8 Disconnect and plug the extension cylinder and

the platform leveling master cylinder hydraulic
hoses. Cap the extension cylinder fittings.

How to Disassemble the

Primary Boom
Complete disassembly of the
primary boom is only necessary if
the outer or inner primary boom
tube must be replaced. The
extension cylinder can be
removed without completely
disassembling the primary boom.
See 3-4, How to Remove the
Extension Cylinder.

Bodily injury hazard. Spraying

hydraulic oil can perforate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.
9 Remove the pin retainer from the master
cylinder barrel-end pivot pin. Use a soft metal
drift and remove the pin.
Leave the master cylinder
attached to the primary boom.
10 Remove the retaining fastener from the primary
boom pivot pin. Do not remove the pin.
11 Remove the hose clamp bolt on the primary
boom, next to the upper mid-pivot.
12 Support the lift cylinder with a lifting device.
13 Remove the pin retainer from the lift cylinder
rod-end pivot pin. Use a soft metal drift to
remove the pin.
The lift cylinder will fall unless it is
supported.
14 Remove the hose and cable clamps from the
underside of the primary boom.
15 Use a slide hammer to remove the primary
boom pivot pin, then carefully lift the primary
boom off the machine.

1 Remove the primary boom. See above, How to

Remove the Primary Boom.
2 Remove the pin retainer from the slave cylinder
rod-end pivot pin. Use a soft metal drift to
remove the pin.
3 Remove the pin retainer from the slave cylinder
barrel-end pivot pin. Use a soft metal drift to
remove the pin, then remove slave cylinder
from the primary boom.
4 Support the platform rotator with a lifting
device.
5 Remove the pin retainer from the platform
rotator pivot pin. Use a soft metal drift to
remove the pin, then remove the platform
rotator from primary boom.
6 Support the master cylinder with a lifting
device.
7 Remove the retaining fastener bolt from the
master cylinder pivot pin. Use a soft metal drift
to remove the pin, then remove the master
cylinder from the primary boom.
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

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Service Manual - First Edition

Section 7 - Repair Procedures

PRIMARY BOOM COMPONENTS

the primary boom weldment.

Crushing hazard. The extension
tube will fall when it is removed
from the primary boom if it is not
properly supported.
10 Remove the extension boom end cap.
11 Remove the fasteners from the extension
cylinder rod-end weldment, then support and
slide the extension cylinder out of the extension
boom.
The bolts that secure the cylinder
rod-end weldment are installed
with Loctite removable thread
sealant. It may be necessary to
heat the bolts and the surrounding
area to remove them. Do not
reuse the bolts.
11 Remove and label the wear pads from the
primary boom weldment and the extension
tube.

3-3
Primary Boom Lift Cylinder
The lift cylinder raises and lowers the primary
boom.

How to Remove the Primary

Boom Lift Cylinder
This procedure requires specific
repair skills, lifting equipment and
a suitable workshop. Attempting
this procedure without these skills
and tools may result in death or
serious injury and significant
component damage. Dealer
service is strongly recommended.
1 Raise the secondary boom and place a 4x4x31
inch (78cm) block between the chassis
counterweight and the upper mid-pivot.
Carefully lower the secondary boom onto the
block.

Pay careful attention to the

location and amount of shims
used with each wear pad.

b
c

a
b
c

7 - 16

Genie Z-45/22

upper mid-pivot
4x4x31 inch block
counterweight

Part No. 29487

Service Manual - First Edition

Section 7 - Repair Procedures

PRIMARY BOOM COMPONENTS

Crushing hazard. When the

barrel-end pivot pin is removed,
the primary lift cylinder will swing
down if it is not properly
supported.

Crushing hazard. Keep hands

away from the block and all
moving parts when lowering the
secondary boom.
2 Raise the primary boom until the end of the
boom is 8 feet (2.5m) off the ground.
3 Support the primary boom with an overhead
crane. Do not lift the primary boom.
4 Disconnect and plug the primary lift cylinder
hydraulic hoses.
Bodily injury hazard. Spraying
hydraulic oil can perforate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.

9 Carefully loosen the straps and allow the

primary lift cylinder to slowly swing down. Now
attach the rod of the primary lift cylinder to an
overhead crane or similar lifting device.
10 Remove the pin retainer from the remaining
pivot pin, then use a soft metal drift to remove
the pin.
Crushing hazard. The primary lift
cylinder will fall if it is not properly
supported.

5 Remove the pin retainer from the pivot pin at

the barrel-end of the primary lift cylinder.
6 Use an overhead crane to lift the primary boom
1 inch (2.5cm). This will relieve pressure on the
barrel-end pivot pin.
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.

a
b

a
b

Part No. 29487

pivot pin
10 to 12 inch rod

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Service Manual - First Edition

Section 7 - Repair Procedures

PRIMARY BOOM COMPONENTS

3-4
Extension Cylinder

a
b

The extension cylinder extends and retracts the

primary boom steel extension tube. It can only be
removed from the platform end of the primary
boom. The extension cylinder is equipped with
counterbalance valves to prevent movement in the
event of a hydraulic line loss.

c
d

How to Remove the

Extension Cylinder
This procedure requires specific
repair skills, lifting equipment and
a suitable workshop. Attempting
this procedure without these skills
and tools may result in death or
serious injury and significant
component damage. Dealer
service is strongly recommended.
1 Raise the secondary boom and place a 4x4x31
inch (78cm) block between the chassis
counterweight and the upper mid-pivot.
Carefully lower the secondary boom onto the
block.
a

a
b
c
d

extension boom end cap

extension boom
extension cylinder rod-end weldment
fasteners
primary boom

2 Raise the primary boom until the extension

boom end cap is 5 feet (1.5m) off the ground.
3 Extend the extension tube to the primary boom
tube 17 inches (43cm). Then secure to prevent
any additional movement
4 Remove the extension boom end cap.
5 Remove the fasteners from the cylinder rodend weldment.
The bolts that secure the cylinder
rod-end weldment are installed
with Loctite removable thread
sealant. It may be necessary to
heat the bolts and the surrounding
area to remove them. Do not
reuse the bolts.

b
c

a
b
c

6 If the function is operational, extend the

extension cylinder until the rod-end weldment
clears the end of the extension tube.

upper mid-pivot
4x4x31 inch block
counterweight

7 Disconnect and plug the extension cylinder

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

Service Manual - First Edition

Section 7 - Repair Procedures

PRIMARY BOOM COMPONENTS

Bodily injury hazard. Spraying

hydraulic oil can perforate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.
8 Remove the fasteners from the extension
cylinder pivot pin, then use a soft metal drift to
remove the pin.

considered, bleed the cylinder to

be sure that there is no air in the
closed loop. See 2-2, How to
Bleed the Slave Cylinder.
1 Remove the end cover from the turntable.
2 Raise the secondary boom and place a 4x4x31
inch (78cm) block between the chassis
counterweight and the upper mid-pivot.
Carefully lower the secondary boom onto the
block.

9 Carefully pull out and properly support the

extension cylinder from the platform end of the
primary boom.

Crushing hazard. The cylinder will

fall if it is not properly supported
when it is pulled out of the
extension tube.

b
c

To make installation the extension

cylinder easier, be sure that the
cylinder rod is extended 3 to 4
feet (1m).

a
b
c

3-5
Platform Leveling Master Cylinder
The master cylinder acts as a pump for the slave
cylinder. Its part of the closed circuit hydraulic
loop that keeps the platform level through the
entire range of primary boom motion. The master
cylinder is located inside the upper mid-pivot at the
base of the primary boom.

How to Remove the Platform

Leveling Master Cylinder

upper mid-pivot
4x4x31 inch block
counterweight

Crushing hazard. Keep hands

away from the block and all
moving parts when lowering the
secondary boom.
3 Extend the primary boom 6 inches (15cm), then
raise the primary boom until it is level.
4 Disconnect and plug the extension cylinder
hydraulic hoses. Cap the ports on the
extension cylinder.

This procedure requires specific

repair skills, lifting equipment and
a suitable workshop. Attempting
this procedure without these skills
and tools may result in death or
serious injury and significant
component damage. Dealer
service is strongly recommended.

Bodily injury hazard. Spraying

hydraulic oil can perforate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.

Before cylinder removal is

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Service Manual - First Edition

Section 7 - Repair Procedures

PRIMARY BOOM COMPONENTS

5 Fully lower the primary boom and support it

with an overhead crane.

Bodily injury hazard. Spraying

hydraulic oil can perforate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.

6 Disconnect and plug the primary lift cylinder

hydraulic hoses. Cap the ports on the primary
lift cylinder.
Bodily injury hazard. Spraying
hydraulic oil can perforate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.
7 Support the barrel-end of the primary lift
cylinder with a strap.
8 Remove the pin retainer from the primary lift
cylinder barrel-end pivot pin.
9 Place a rod through the barrel-end pivot pin
and twist to remove the pin.

12 Remove the retaining fastener from the

platform leveling master cylinder rod-end pivot
pin, then use a slide hammer to remove the
pin.
13 Attach a strap to the rod-end of the platform
leveling master cylinder.
14 Remove the pin retainer from the platform
leveling master cylinder barrel-end pivot pin.
Then support the cylinder with the strap.
15 Place a rod through the barrel-end pivot pin
and twist to remove the pin.
Crushing hazard. The cylinder will
fall if it is not supported when the
pivot pin is removed.

a
b
a
a
b

pivot pin
10 to 12 inch (30cm) rod

10 Carefully lower and rest the barrel-end of the

primary lift cylinder on the turntable
counterweight.
11 Disconnect and plug the platform leveling
master cylinder hydraulic hoses. Cap the
fittings on the master cylinder.

7 - 20

a
b

pivot pin
10 to 12 inch (30cm) rod

16 Carefully lower the platform leveling master

cylinder down and out of the upper mid-pivot.

Genie Z-45/22

Part No. 29487

Service Manual - First Edition

Section 7 - Repair Procedures

Secondary Boom Components

a

g
h

l
k
i
j

4-1
Secondary Boom
How to Disassemble the
Secondary Boom
The procedures in this section
require specific repair skills, lifting
equipment and a suitable
workshop. Attempting this
procedure without these skills and
tools may result in death or
serious injury and significant
component damage. Dealer
service is required.
Follow the disassembly steps to the point required
to complete the repair. Then re-assemble the
secondary boom by following the disassembly
steps in reverse order.

Part No. 29487

Genie Z-45/22

Secondary Boom
a
upper secondary boom
(number 1 arm)
b
upper tension link
(number 2 arm)
c
lower tension link
(number 3 arm)
d
lower secondary boom
(number 4 arm)
e
secondary lift cylinder
f
pin retainer
g
compression link
h
lower mid-pivot
i
drive limit switch
j
primary boom rest
k
turntable pivot
l
upper mid-pivot rest
m upper mid-pivot

7 - 21

Service Manual - First Edition

Section 7 - Repair Procedures

SECONDARY BOOM COMPONENTS

1 Remove the platform. See 2-1, How to Remove

the Platform.
2 Remove the primary boom. See 3-2, How to
Remove the Primary Boom.
a

Crushing hazard. Do not remove

the 4x4x31 inch (78cm) support
block installed during primary
boom removal.
a

a
b

pivot pin
10 to 12 inch (30cm) rod

6 Remove the turntable end cover.

7 Be sure that the upper mid-pivot rest is in the

industrial tire position.
Machines equipped with:

a
b
c

Rough terrain tires. Move the upper mid-pivot

rest up into the industrial tire position on the
mid-pivot.

upper mid-pivot
4x4x31 inch block
counterweight

Industrial tires. No modification is necessary.

a

3 Use an overhead crane to attach a lifting strap

to the rod-end of the primary lift cylinder. Then
raise the primary lift cylinder with the crane, to
a vertical position.

b
d

4 Remove the pin retainer from the pivot pin at

the barrel-end of the primary lift cylinder.

5 Place a rod through the barrel-end pivot pin

and twist to remove the pin. Remove the
primary lift cylinder from the machine.
Crushing hazard. The primary lift
cylinder will fall if it is not properly
supported when the barrel-end
pivot pin is removed.

a
b
c
d

upper mid-pivot
mounting position holes for
rough-terrain tire models
upper mid-pivot rest
mounting position holes for
industrial tire models

8 Attach the lifting strap from an overhead crane

to the number 1 arm at the end nearest the
upper mid-pivot and lift to support.
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

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Section 7 - Repair Procedures

SECONDARY BOOM COMPONENTS

11 Lift the number 1 arm until the secondary lift

cylinders can swing forward to rest on the
lower mid-pivot.
12 Remove the block between the counterweight
and the upper mid-pivot.
13 Lower the arms enough to relieve the pressure
on the compression link upper pivot pin.

21 Pull all of the electrical cables out of the plastic

cable track. Do not pull out the hydraulic
cables.
22 Disconnect and plug the platform rotator
hydraulic hoses at the union, located near the
upper mid-pivot. Remove the cable track
assembly from the machine.

Specification: to remove pressure on the

compression link
Industrial tires

20 Open the platform control box and label each

wire termination from the cables. Disconnect all
control cable wiring from the platform control
box.

The upper mid-pivot rest should

be approximately 1 inch (2.5cm)
above the rest block.

Rough terrain tires

Bodily injury hazard. Spraying

hydraulic oil can perforate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.

The upper mid-pivot rest should

be approximately 4 inches
(10cm) above the rest block.

14 Remove the pin retaining fastener from the

compression link to number 1 arm pivot pin.
Use a soft metal drift to remove the pin.

23 Remove the upper and lower cable trays from

the number 2 arm. Also remove the upper
cable tray from the number 3 arm.

15 Lower the arms to full rest and re-position the

lifting strap to the center of the number 1 arm.

24 Pull all of the cables and hoses down through

the upper mid-pivot.

16 Remove the pin retaining fastener from the

lower mid-pivot to number 1 arm pivot pin. Use
a soft metal drift to remove the pin.
17 Remove the pin retaining fastener from the
upper mid-pivot to number 1 arm pivot pin. Use
a slide hammer to remove the pin.
Crushing hazard. If the overhead
crane is not properly attached, the
number 1 arm may become
unbalanced and fall when it is
disconnected from the upper
mid-pivot.
18 Carefully remove the number 1 arm from the
machine.

Component damage hazard.

Cables and hoses can be
irreparably damaged if they are
kinked or pinched.
25 Attach a lifting strap from an overhead crane to
the upper mid-pivot. Then place a hydraulic
jack between arm numbers 2 and 3 at the end
nearest the upper mid-pivot end of the arms.
26 Adjust the hydraulic jack and overhead crane to
relieve the pressure on the pivot pin connecting
the number 2 arm to the upper mid-pivot.
27 Remove the pin retaining fastener from the
upper mid-pivot to number 2 arm pivot pin. Use
a slide hammer to remove the pin.

19 Number each electrical cable and its entry

location at the platform control box.

Part No. 29487

Crushing hazard. The upper

mid-pivot will fall if it is not
properly supported when the pivot
pin is removed.

Genie Z-45/22

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Service Manual - First Edition

Section 7 - Repair Procedures

SECONDARY BOOM COMPONENTS

28 Carefully lift and remove the upper mid-pivot

from the machine.
29 Position the lifting strap from an overhead
crane at the center of the number 2 arm.

30 Remove the pin retaining fastener from the

lower mid-pivot to number 2 arm pivot pin. Use
a soft metal drift to remove the pin.

Crushing hazard. If the overhead

crane is not properly attached, the
number 2 arm may become
unbalanced and fall when it is
disconnected from the mid-pivot.

a
b

Crushing hazard. The secondary

lift cylinders will fall when the
barrel-end pivot pins are removed
if they are not properly supported.

31 Carefully remove the number 2 arm from the

machine.
32 Remove the two cable clamps from the inside
of the lower mid-pivot.
33 Disconnect and remove the drive speed limit
switch from the primary boom rest.
34 Disconnect and plug the hydraulic hoses at the
secondary lift cylinders.
Bodily injury hazard. Spraying
hydraulic oil can perforate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.
35 Remove the pin retainers from each secondary
lift cylinder barrel-end pivot pin.
36 Place a rod through each barrel-end pivot pin
and twist to remove the pin. Remove each
secondary lift cylinder from the machine.

pivot pin
10 to 12 inch (30cm) rod

37 Remove the lower cable tray from the

number 3 arm.
38 Pull all of the cables and hoses through the
lower mid-pivot and out of the turntable pivot.
Component damage hazard.
Cables and hoses can be
irreparably damaged if they are
kinked or pinched.
39 Attach the strap from an overhead crane to the
top tube of the lower mid-pivot. Then place a
hydraulic jack between arm numbers 3 and 4 at
the end nearest the lower mid-pivot.
40 Remove the pin retaining fastener from the
lower mid-pivot to number 3 arm pivot pin. Use
a soft metal drift to remove the pin.
41 Carefully lower the lower mid-pivot and
compression link away from the machine to a
resting position.
42 Position the lifting strap from an overhead
crane at the center of the number 3 arm.

7 - 24

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Part No. 29487

Service Manual - First Edition

Section 7 - Repair Procedures

SECONDARY BOOM COMPONENTS

43 Remove the pin retaining fastener from the

turntable pivot to number 3 arm pivot pin. Use
a slide hammer to remove the pin.
Crushing hazard. If the overhead
crane is not properly attached, the
number 3 arm may become
unbalanced and fall when it is
disconnected from the turntable
pivot.
44 Carefully remove the number 3 arm from the
machine.
45 Position the strap from an overhead crane
around the top tube of the lower mid-pivot and
then carefully lift the lower mid-pivot until it is
vertical.

48 Lower the compression link to a resting

position. Then attach the lifting strap from an
overhead crane to the compression link and
raise it to a vertical position.
49 Remove the pin retaining fastener from the
compression link to number 4 arm pivot pin.
Use a soft metal drift to remove the pin
50 Remove the compression link.
51 Position the lifting strap from an overhead
crane at the center of the number 4 arm.
52 Remove the pin retaining fastener from the
turntable pivot to number 4 arm pivot pin. Use
a slide hammer to remove the pin.
Crushing hazard. If the overhead
crane is not properly attached, the
number 4 arm may become
unbalanced and fall when it is
disconnected from the turntable
pivot.
53 Carefully remove the number 4 arm.

46 Remove the pin retaining fastener from the

lower mid-pivot to number 4 arm pivot pin. Use
a soft metal drift to remove the pin.
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

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Service Manual - First Edition

Section 7 - Repair Procedures

SECONDARY BOOM COMPONENTS

Bodily injury hazard. Spraying

hydraulic oil can perforate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.

4-2
Secondary Boom Lift Cylinders
There are two boom lift cylinders incorporated in
the structure of the secondary boom assembly.
These cylinders operate in parallel and require
hydraulic pressure to extend and retract. Each
secondary boom lift cylinder is equipped with a
counterbalance valves to prevent movement in the
event of a hydraulic line failure. A 1200 psi (83
bar) relief valve for the down function is located on
the boom function manifold.

3 Remove the pin retainers from each secondary

lift cylinder rod-end pivot pin.
4 Place a rod through the rod-end pivot pin and
twist to remove the pin.

How to Remove the Secondary

Lift Cylinders
a

This procedure requires specific

repair skills, lifting equipment and
a suitable workshop. Attempting
this procedure without these skills
and tools may result in death or
serious injury and significant
component damage. Dealer
service is strongly recommended.
1 Lower the secondary boom to full rest, then
raise the primary boom just above the drive
limit switch.

a
b

pivot pin
10 to 12 inch (30cm) rod

5 Loosen, but do not remove, the counterbalance

valve to fully retract the cylinder.
The counterbalance valve is
pre-set from the factory. Do not
adjust this valve.
6 Remove the pin retainer from the pivot pins at
the barrel-ends of each secondary lift cylinder.
7 Place a rod through each barrel-end pivot pin
and twist to remove the pins. Remove the
secondary lift cylinders from the machine.

a
a

drive limit switch

2 Disconnect and plug the hydraulic hose and

steel lines for each secondary lift cylinder.

Crushing hazard. The secondary

lift cylinders will fall when the
barrel-end pivot pins are removed
if they are not properly supported.
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

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Part No. 29487

Service Manual - First Edition

Section 7 - Repair Procedures

Turntable Covers
5-1
Turntable Covers
How to Remove a Turntable Cover
1 Raise the turntable cover. Support the open
cover with an overhead crane or forklift.
Do not lift.
Crushing hazard. Due to its heavy
weight, do not attempt to support
the cover by hand.
2 Remove the upper and lower retaining clips
from the gas strut.
3 Gently pry the strut pivot sockets off of the ball
studs and remove the strut.
4 Remove the fasteners from the cover hinge
pins.
5 Raise the cover slightly to relieve the pressure
on the cover hinge pins.
6 Remove the cover hinge pins.
7 Carefully lift and remove the cover from the
machine.
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

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Service Manual - First Edition

Section 7 - Repair Procedures

Kubota V1702-B Engine

6-1
Timing Adjustment

How to Install the Flex Plate

Complete information to perform this procedure is

available in the Kubota V1702-B Diesel Engine
Workshop Manual (Kubota code number: 9789700691). Genie part number 29587.

1 Install the flex plate onto the flywheel with the

raised spline against the flywheel.
2 Install the coupler onto the pump shaft with the
set screw towards the pump. Leave a 1/4 inch
(0.635mm) gap between the coupler and pump
end plate.
3 Apply removable Loctite removable thread
sealant to the coupler set screw. Torque the
set screw to 36 ft-lbs (49 Nm).

6-2
Glow Plugs

Component damage hazard. Do

not force the drive pump during
re-installation or the flex plate
teeth may become damaged.

How to Check the Glow Plugs

See the scheduled maintenance procedure B-11,
Check The Glow Plugs - Diesel Models.

6-3
RPM Adjustment
See the scheduled maintenance procedure B-13,
Check and Adjust the Engine RPM.

6-4
Flex Plate
The flex plate acts as a coupler between the
engine and the pump. It is bolted to the engine
flywheel and has a splined center to drive the
pump.

6-5
Water Temperature and Oil
Pressure Switches
The water temperature switch is a normally open
switch that closes at approximately 225 F
(107 C). When this switch closes, the engine is
shut off to prevent damage and will not restart until
the temperature drops below the switch point. An
over-temperature indicator light at the ground at
platform controls should turn on when the switch
closes.
Component damage hazard. Do
not crank the engine with the
over-temperature light on.

How to Remove the Flex Plate

1 Disconnect the wiring plug at the electronic
displacement controller (EDC), located on the
drive pump.
2 Support the drive pump with an appropriate
lifting device. Then remove all of the pump
mounting plate to engine bell housing bolts.

The oil pressure switch is a normally closed switch

that opens at approximately 7.1 psi (0.5 bar). If the
oil pressure drops below the switch point, the
switch closes and shuts off the engine. A low oil
pressure indicator light at the ground and platform
controls should turn on when the switch closes.

3 Carefully pull the pump away from the engine

and secure it from moving.
4 Remove the flex plate mounting fasteners, then
remove the flex plate from the engine.
7 - 28

Genie Z-45/22

Component damage hazard. Do

not start or continue to run the
engine with the low oil pressure
light on.
Part No. 29487

Service Manual - First Edition

Section 7 - Repair Procedures

KUBOTA V1702-B ENGINE

2 Disconnect the wiring from the desired switch.

3 Remove the switch from the engine block, and

then install the new switch. Do not over tighten.
Burn hazard. Contact with hot
engine fluids or components may
cause severe burns.
Always use pipe thread sealant
when installing a switch.
Specifications
Water temperature switch

a
b

Torque

8-18 foot-pounds
11-24 Newton meters

Hex size

13/16 inch

Temperature switch point

225 F (107 C) 2%

Oil pressure switch

water temperature switch

oil pressure switch

How to Remove the Water

Temperature and Oil Pressure
Switches

Torque

8-18 foot-pounds
11-24 Newton meters

Hex size

1-1/16 inch

Oil pressure switch point

7.1 psi (0.5 bar)

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.

a
a
a
a

Part No. 29487

pivot plate bolts

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Service Manual - First Edition

Section 7 - Repair Procedures

Ford LSG 423 Engine

b

70
f

7-1
Governor Actuator

Governor Actuator and Linkage

a
clevis yoke
b
linkage rod
c
carburetor
d
throttle plate shaft
e
governor actuator
f
actuator shaft
g
actuator arm

How to Set Up the Governor

Actuator and Linkage
Adjustment of the governor
actuator is only necessary when
the governor actuator or the
linkage has been replaced.
1 Connect the linkage rod to the throttle plate
shaft, then tighten the lock nut.
2 Fasten the lock nut and clevis yoke to the
linkage rod. Do not tighten the lock nut against
the clevis yoke.
3 Loosen the fastener on the actuator arm.
Rotate the actuator arm until it is at a 70
degree angle to the linkage rod.

7 - 30

4 Position the linkage rod so that the throttle is in

the idle position. Then adjust the clevis yoke on
the linkage rod to obtain the proper length.
Install the yoke onto the actuator arm and
tighten the lock nut.
5 With the throttle in the idle position and the
actuator arm at a 70 degree angle to the
linkage, rotate the actuator shaft slightly
counterclockwise to pre-load the spring.
Tighten the fastener on the actuator arm
without releasing the shaft.

Genie Z-45/22

Part No. 29487

Service Manual - First Edition

Section 7 - Repair Procedures

FORD LSG 423 ENGINE

6 Manually pull the actuator arm through a full

cycle to be sure that the linkage moves freely.
Be sure that the linkage activates the throttle
shaft to approximately half throttle.
The linkage must be free of
friction and obstruction. Do not let
it rub against the engine, brackets
or hoses.
If the throttle linkage is improperly
adjusted and allowed to reach full
throttle, the engine will over-rev
and cause component damage.

Automatic Choke Without

Poppet Valve
This choke functions in both gasoline and propane
mode.
Adjusting the choke to a rich mixture for cold
climates will hamper engine performance when
starting a cold engine on propane fuel. To avoid
this problem, start the engine in gasoline mode.
After the engine reaches normal operating
temperature, select propane mode.
rich

lean

7-2
Choke Adjustments
This engine is equipped with one of three different
choke configurations. Early models were equipped
with manual chokes. They were replaced with
electrically heated automatic chokes. These
chokes were improved with the addition of a
poppet valve to enhance cold starting ability on
propane fuel.
The machine is equipped with an automatic choke
if there is not a choke switch on the control panel.
Choke adjustments are affected
by climate. Richer adjustment will
be necessary in colder climates,
leaner adjustment in warmer
climates.

Manual Choke
The manual choke is solenoid operated and is only
operational in the gasoline mode. This choke will
not operate in propane mode.

A flow path past the choke butterfly is required if

the engine is to be cold started in the propane
mode. A inch (6mm) flow path is recommended.
Adjust the choke only when the engine and choke
are cold.

Automatic Choke With Poppet

Valve
This choke functions in both gasoline and propane
mode. The choke butterfly may be adjusted to a
fully closed (rich) position for colder climates and
the poppet valve will provide a flow path during
propane fueled operation.

Component damage hazard.

During adjustments, do not allow
the choke butterfly to stop the
solenoid from fully retracting. The
plunger must be able to bottomout inside the solenoid housing.

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Section 7 - Repair Procedures

FORD LSG 423 ENGINE

7-3
Timing Adjustment

4 Disconnect the wiring plug at the electronic

displacement controller (EDC), located on the
drive pump.

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.

5 Remove the mounting fasteners from the

regulator mounting bracket, then pull the
bracket up past the bell housing. Secure the
bracket before continuing.
6 Support the drive pump with an appropriate
lifting device. Then remove all of the pump
mounting plate to engine bell housing bolts.

7-4
Carburetor Adjustment
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.

7 Carefully pull the pump away from the engine

and secure it from moving.
8 Remove the flex plate mounting fasteners, then
remove the flex plate from the engine.

How to Install the Flex Plate

1 Install the flex plate onto the flywheel with the
raised spline against the flywheel.

7-5
RPM Adjustment
See the scheduled maintenance procedure B-13,
Check and Adjust the Engine RPM.

2 Install the coupler onto the pump shaft with the

set screw towards the pump. Leave a 1/4 inch
(0.635mm) gap between the coupler and pump
end plate.
3 Apply removable Loctite thread sealant to the
coupler set screw. Torque the set screw to
36 ft-lbs (49 Nm).

7-6
Flex Plate
The flex plate acts as a coupler between the
engine and the pump. It is bolted to the engine
flywheel and has a splined center to drive the
pump.

Component damage hazard. Do

not force the drive pump during
re-installation or the flex plate
teeth may become damaged.

Flex Plate Removal

1 Disconnect and remove the hose between the
carburetor venturi and the air cleaner.
2 Disconnect and remove the muffler support
bracket.
3 Disconnect the linkage from the governor, then
remove the governor linkage from the
carburetor. Do not alter the length of the
linkage.

7 - 32

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Part No. 29487

Service Manual - First Edition

Section 7 - Repair Procedures

FORD LSG 423 ENGINE

7-7
Water Temperature and Oil
Pressure Switches

How to Remove the Water

Temperature and Oil Pressure
Switches

The water temperature switch is a normally open

switch that closes at approximately 230 F
(112 C). When this switch closes, the engine is
shut off to prevent damage and will not restart until
the temperature drops below the switch point. An
over-temperature indicator light at the ground and
platform controls should turn on when the switch
closes.
Component damage hazard. Do
not crank the engine with the
over-temperature on.
The oil pressure switch is a normally closed switch
that opens at approximately 3 to 5 psi
(0.21 to 0.34 bar). If the oil pressure drops below
the switch point, the switch closes and shuts off
the engine. A low oil pressure indicator light at the
ground and platform controls should turn on when
the switch closes.
Component damage hazard. Do
not start or continue to run the
engine with the low oil pressure
light on.

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.
2 Disconnect the wiring from the desired switch.
3 Remove the switch from the engine block, and
then install the new switch. Do not over tighten.
Burn hazard. Contact with hot
engine fluids or components may
cause severe burns
Always use pipe thread sealant
when installing a switch.
Specifications
Water temperature switch
Torque

8-18 foot-pounds
11-24 Newton meters

Hex size

13/16 inch

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)

a
b

Part No. 29487

oil pressure switch

water temperature switch

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Service Manual - First Edition

Section 7 - Repair Procedures

FORD LSG 423 ENGINE

7-8
Vacuum Switch
How to Test the Vacuum Switch
a

d
a
b
c
d

ohmmeter
common terminal (SOL.)
vacuum switch
normally open terminal (ING.)

1 Connect the leads from an ohmmeter or

continuity tester to the common and normally
open terminals.
Result: There should be no continuity
(infinite ).
2 Apply mild suction to the vacuum port.
Result: The switch should close and show full
continuity (zero ).
Component damage hazard. Do
not short vacuum switch terminals
to ground.

7 - 34

Genie Z-45/22

Part No. 29487

Service Manual - First Edition

Section 7 - Repair Procedures

Ground Controls
8-1
Control Relays

Test

Desired result

terminal 13 to 14

160 to 170

Relays used for single function switching are

single pole double throw (SPDT) switches. Two
function switching requires a double pole double
throw (DPDT) relay.

terminal 8 to 5,4,1,12 & 9

no continuity
(infinite )

terminal 5 to 8,4,1,12 & 9

no continuity

terminal 4 to 8,5,1 & 9

no continuity

How to Test a Double Pole Double

Throw Relay

terminal 1 to 8,5,4 & 12

no continuity

terminal 4 to 12

continuity (zero )

This procedure covers fundamental relay testing

and does not specifically apply to all varieties of
relays.

terminal 1 to 9

continuity

1 Turn the keyswitch to the off position and

remove the key.

4 Connect 12V DC to terminal 14 and a ground

wire to terminal 13, then test the following
terminal combinations.

2 Label and then disconnect all the wiring from

the relay to be tested.
3 Connect the leads from an ohmmeter to each
terminal combination and check for continuity.
Terminals 13 and 14 represent the coil and
should not be tested in any other combination.

Test

Desired result

terminal 8 to 1,5,9 & 4

no continuity
(infinite )

terminal 5 to 1,4,8 & 12

no continuity

terminal 4 to 1,5,9,8 & 12

no continuity

terminal 1 to 5,9,4,8 & 12

no continuity

terminal 8 to 12

continuity (zero )

terminal 5 to 9

continuity

e
a
b
c
d
e
f
g
h
i

Part No. 29487

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

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Service Manual - First Edition

Section 7 - Repair Procedures

GROUND CONTROLS

How to Test a Single Pole Double

Throw Relay

8-2
Toggle Switches

This procedure covers fundamental relay testing

and does not specifically apply to all varieties of
relays.

See 1-4, Toggle Switches.

1 Turn the keyswitch to the off position and

remove the key.

8-3
Wago Components

2 Label and then disconnect all the wiring from

the relay to be tested.
3 Connect the leads from an ohmmeter or
continuity tester to each terminal combination
and check for continuity. Terminals 13 to 14
represent the coil and should not be tested in
any other combination.
Test

Desired result

terminal 13 to 14

190 to 200

terminal 5 to 1 & 9

no continuity
(infinite )

terminal 1 to 9

continuity (zero )

Desired result

terminal 1 to 5 & 9

no continuity
(infinite )

terminal 5 to 9

continuity (zero )

7 - 36

Electrocution hazard. Contact with

hot or live circuits may result in
death or serious injury. Remove
all rings, watches and other
jewelry.
A small standard screw driver is
provided and should be used
when removing a Wago
component. This screwdriver is
located in the instruction manual
storage box in the platform.

4 Connect 12V DC to terminal 14 and a ground

wire to terminal 13, then test the following
terminal combinations.
Test

How to Remove a Wago

Component

1 Label and then disconnect the wiring from the

component to be removed.
2 Locate the removal tab on the bottom or top
side of the component.
3 Use the provided screwdriver to gently pry up
on the tab of the component and remove it.

Genie Z-45/22

Part No. 29487

Service Manual - First Edition

Section 7 - Repair Procedures

GROUND CONTROLS

8-4
Resistors
How to Test the Resistors
Two resistors are used to maintain proper control
of boom function speeds. A 10 ohm resistor
reduces voltage to all the boom function switches.
A 15 ohm resistor parallels the 10 ohm resistor to
reduce the voltage to the turntable rotate switch.
Turn the key switch to the off
position and remove the key.
1 Disconnect one of the resistor wires from the
resistor or the opposite end terminal.
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

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Service Manual - First Edition

Section 7 - Repair Procedures

Relay Panel
9-1
Control Relays

Test

Desired result

terminal 85 to 86

85 to 95

How to Test a Single Pole Double

Throw Relay

terminal 87 to 87a & 30

no continuity
(infinite )

terminal 87a to 30

continuity (zero )

Electrocution hazard. Contact with

hot or live circuits may result in
death or serious injury. Remove
all rings, watches and other
jewelry.
1 Label and then disconnect all the wiring from
the relay to be tested.
2 Connect the leads from an ohmmeter or
continuity tester to each terminal combination
and check for continuity. Terminals 85 to 86
represent the coil and should not be tested in
any other combination.

3 Connect 12V DC to terminal 85 and a ground

wire to terminal 86, then test the following
terminal combinations.
Test

Desired result

terminal 87a to 87 & 30

no continuity
(infinite )

terminal 87 to 30

continuity (zero )

a
b
c
d
e

7 - 38

terminal no. 87A

terminal no. 85
terminal no. 30
terminal no. 86
terminal no. 87

Genie Z-45/22

Part No. 29487

Service Manual - First Edition

Section 7 - Repair Procedures

RELAY PANEL

9-2
Power Relay

Electrocution hazard. Contact with

hot or live circuits may result in
death or serious injury. Remove
all rings, watches and other
jewelry.

How to Test the Power Relay

Electrocution hazard. Disconnect
the ground cable from the battery
before performing this procedure.
1 Connect the leads from an ohmmeter to each
terminal combination and check for continuity.
Test

Desired result

2 small posts

13 to 17

2 large posts

no continuity
(infinite )

Any small post to

any large post

no continuity
(infinite )

high amp power contact terminals

(large posts)

solenoid activate coil terminals

(small posts)

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

2 large posts

continuity (zero )

Part No. 29487

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Service Manual - First Edition

Section 7 - Repair Procedures

Hydraulic Pumps
6 Remove the pressure gauge and reconnect the
hydraulic hose.

10-1
Lift/Steer Pump
How to Test the Lift/Steer Pump
1 Gasoline/LPG models: Remove the coil wire
from the distributor cap.
Diesel models: Disconnect the 3 wires from
the fuel on solenoid at the fuel injector pump.
Electrocution hazard. Contact with
hot or live circuits may result in
death or serious injury. Remove
all rings, watches and other
jewelry.

7 Gasoline/LPG models: Reconnect the coil

wire to the distributor cap.
Diesel models: Reconnect the wiring to the
fuel on solenoid.

How to Remove the Lift/Steer

Pump
1 Close the two hydraulic tank valves located at
the main pump.

2 Disconnect the high pressure hydraulic hose

from the pump and cap it.
Burn hazard. Contact with hot oil
may cause severe burns.
open

3 Connect a 0 to 5000 psi (0 to 350 bar) pressure

gauge to the high pressure port on the pump.
4 Turn the key switch to ground control and pull
the Emergency Stop button to the on position.

2 Disconnect the hydraulic hoses from the pump

and cap them.
Bodily injury hazard. Spraying
hydraulic oil can perforate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.

5 Observe the pressure gauge while cranking the

engine. Immediately stop cranking if the
pressure reaches or exceeds 3000 psi
(206 bar).
Hydraulic pressure in excess of
3000 psi (206 bar) will cause
severe component damage.

3 Remove the pump mounting bolts. Carefully

remove the pump.

Result: If the pressure gauge reads 3000 psi

(206 bar), immediately stop cranking the
engine. The pump is good.
Result: If pressure fails to reach 3000 psi
(206 bar), the pump is bad and will need to be
replaced.

7 - 40

closed

Genie Z-45/22

Component damage hazard. Be

sure to open the two hydraulic
tank valves after re-installing the
pump.

Part No. 29487

Service Manual - First Edition

Section 7 - Repair Procedures

HYDRAULIC PUMPS

3 Disconnect the hydraulic hoses from the pump

and cap them.

10-2
Drive Hydraulic Pump
The drive hydraulic pump is a bi-directional
variable displacement piston pump. The pump
output is controlled by the electronic displacement
controller (EDC), located on the pump. The only
adjustment that can be made to the pump is the
neutral or null adjustment. Any internal service to
the pump should only be performed at an
authorized Sundstrand-Sauer service center.

Bodily injury hazard. Spraying

hydraulic oil can perforate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.
4 Support the pump and remove the two pump
mounting bolts. Carefully remove the pump.

How to Remove the Drive

Hydraulic Pump

Be sure to open the two hydraulic

tank valves and prime the pump
after installing the pump.

The work area and surfaces

where this procedure will be
performed must be clean and free
of debris that could get into the
hydraulic system and cause
severe component damage.
Dealer service is recommended.

How to Prime the Pump

1 Gasoline/LPG models: Disconnect the ignition
coil wire and isolate it from ground.
Diesel models: Disconnect the wiring to the
injection pump fuel-on solenoid
2 Crank the engine with the starter motor for 15
seconds.

1 Disconnect the electrical connection at the

electronic displacement controller (EDC)
located on the main pump.
2 Close the two hydraulic tank valves located at
the main pump.

open

Part No. 29487

closed

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Section 7 - Repair Procedures

Function Manifold
11-1
Function Manifold Components
Index
No.

Description

Schematic
Item

Counterbalance valve ........................ Z ........... Platform leveling cylinder - extend ... 10-12 ft-lbs / 15-18Nm

3 position 4 way D01 valve ............... D ........... Platform level .................................... 30-35 in-lbs / 3-4 Nm

Counterbalance valve ........................ Y ........... Turntable rotate - right ...................... 10-12 ft-lbs / 15-18Nm

Function

Torque

3 position 4 way valve ....................... F ........... Turntable rotate ................................ 30-35 in-lbs / 3-4 Nm

3 position 4 way valve ....................... C ........... Secondary up/down .......................... 30-35 in-lbs / 3-4 Nm

3 position 4 way valve ....................... B ........... Primary up/down ............................... 30-35 in-lbs / 3-4 Nm

Counterbalance valve ........................ AY ......... Turntable rotate - left ........................ 10-12 ft-lbs / 15-18Nm

Check valve ....................................... P ........... Secondary flow regulator .................. 11-13 ft-lbs / 15-18 Nm

Check valve ....................................... AB ......... Primary flow regulator ....................... 11-13 ft-lbs / 15-18 Nm

10

Check valve ....................................... AA ......... Extend/Retract flow regulator ........... 11-13 ft-lbs / 15-18 Nm

11

3 position 4 way valve ....................... A ........... Extend/Retract .................................. 30-35 in-lbs / 3-4 Nm

12

Flow regulator valve .......................... L ........... Extend/Retract .................................. 10-12 ft-lbs / 14-16 Nm

13

Flow regulator valve .......................... M .......... Primary .............................................. 10-12 ft-lbs / 14-16 Nm

14

Relief valve, 1200 psi (83 bar) .......... T ........... Primary down .................................... 25-30 ft-lbs / 34-41 Nm

15

Flow regulator valve .......................... N ........... Secondary ......................................... 10-12 ft-lbs / 14-16 Nm

16

Relief valve, 1200 psi (83 bar) .......... U ........... Secondary down ............................... 25-30 ft-lbs / 34-41 Nm

17

Flow regulator valve .......................... O ........... Swing ................................................ 10-12 ft-lbs / 14-16 Nm

18

Proportional solenoid valve ............... G ........... Extend/Retract .................................. 10-12 ft-lbs / 14-16 Nm

19

Proportional solenoid valve ............... H ........... Primary .............................................. 10-12 ft-lbs / 14-16 Nm

20

Proportional solenoid valve ............... I ............ Secondary ......................................... 10-12 ft-lbs / 14-16 Nm

21

Proportional solenoid valve ............... K ........... Swing ................................................ 10-12 ft-lbs / 14-16 Nm

22

Differential sensing valve .................. S ........... All functions ....................................... 10-12 ft-lbs / 14-16 Nm

23

Orifice 0.030 in / 0.76mm .................. AG ........ Platform rotate

24

Normally closed poppet valve ........... R ........... Platform level .................................... 25-30 ft-lbs / 34-41 Nm

25

Normally closed poppet valve ........... Q ........... Platform rotate .................................. 25-30 ft-lbs / 34-41 Nm

26

Relief valve, 2200 psi (152 bar) ........ AF ......... All functions ....................................... 35-40 ft-lbs / 47-54 Nm

27

Priority flow regulator valve ............... AE ......... Steering ............................................. 10-12 ft-lbs / 14-16 Nm

28

Check valve ....................................... AC ........ Platform rotate flow regulator ........... 11-13 ft-lbs / 15-18 Nm

29

Orifice 0.015 in / 0.38mm .................. V ........... Differential sensing

30

Check valve ....................................... AD ........ Platform level flow regulator ............. 11-13 ft-lbs / 15-18 Nm

31

Check valve ....................................... J ............ Swing flow regulator ......................... 11-13 ft-lbs / 15-18 Nm

32

Counterbalance valve ........................ AZ ......... Platform leveling cylinder - retract .... 10-12 ft-lbs / 15-18 Nm

33

3 position 4 way valve ....................... E ........... Platform rotate .................................. 30-35 in-lbs / 3-4 Nm

7 - 42

Genie Z-45/22

Part No. 29487

Service Manual - First Edition

Section 7 - Repair Procedures

FUNCTION MANIFOLD

7
8
33

32

10

31

11

30
29
28

12
13
14

27
15
26
16
17

18
19
20
21

25

Part No. 29487

24

23

22

Genie Z-45/22

7 - 43

Service Manual - First Edition

Section 7 - Repair Procedures

FUNCTION MANIFOLD

6 Restart the engine. Hold the retract switch and

recheck the valve pressure.

Plug Torque Specifications

Description

Torque

SAE No. 2

4.2 ft-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

Specifications
Main relief valve pressure

How to Adjust the Primary or

Secondary Boom Down Relief
Valve
1 Connect a 0 - 3000 psi (0 to 206 bar) pressure
gauge to the diagnostic nipple on the function
manifold.

11-2
Valve Adjustments - Function
Manifold

2 Start the engine from the ground controls and

then fully lower the boom to be adjusted.
3 Hold the primary or secondary boom up/down
switch in the down position and observe the
pressure reading on the pressure gauge.

How to Adjust the Main Relief

Valve
1 Connect a 0 - 3000 psi (0 to 206 bar) pressure
gauge to the diagnostic nipple on the function
manifold.
2 Start the engine from the ground controls and
then completely retract the primary boom.

4 Turn the engine off. Hold the relief valve and

remove the cap (item 14 for primary boom,
item 16 for secondary boom).
5 Adjust the internal hex socket. Turn it clockwise
to increase the pressure or counterclockwise to
decrease the pressure. Then reinstall the relief
valve cap.

3 Hold the retract switch and observe the

pressure reading on the pressure gauge.

Tip-over hazard. Do not adjust the

relief valves higher than
recommended. They are set to
prevent a tip-over or damage to lift
linkage.

4 Turn the engine off. Hold the relief valve and

remove the cap (item 26).
5 Adjust the internal hex socket. Turn it clockwise
to increase the pressure or counterclockwise to
decrease the pressure. Then reinstall the relief
valve cap.
Tip-over hazard. Do not adjust the
relief valves higher than
recommended. They are set to
prevent a tip-over or damage to lift
linkage.

7 - 44

2200 psi / 152 bar

6 Restart the engine. Hold the primary or

secondary boom up/down switch in the down
position and recheck the valve pressure.
Specifications
Relief valve pressure

Genie Z-45/22

1200 psi / 83 bar

Part No. 29487

Service Manual - First Edition

Section 7 - Repair Procedures

FUNCTION MANIFOLD

How to Override a Valve

A hydraulic valve may need to be manually
overridden to troubleshoot a malfunction. Each
proportional boom function uses a variable
position proportional valve and a three position
directional valve. Example: one position for boom
up, one position for neutral and one position for
boom down. The platform rotate and level
functions use a three position valve and a two
position poppet valve. The three position valves
and the proportional valves can be manually
overridden. To identify the manifold valves see
11-1 Function Manifold Components in this
section.

How to Check the Resistance of a

Valve Coil
1 Turn the keyswitch to the off position and
disconnect the wires from the valve coil to be
tested.
2 Connect the leads from an ohmmeter to the
valve coil terminals.

1 Push the button on the end of the valve in

inch (6mm).
2 Move the ground control function switch for the
function being overridden to operate function.
Collision Hazard. Impact with
moving boom components may
cause death or serious injury. Use
extreme caution when overriding a
boom function and know the
direction of intended travel.

Specifications
Valve

Resistance

Proportional solenoid valve

3 pos 4 way directional valve

4.5

Normally closed
poppet valve

c
a
b
c

Part No. 29487

directional valves
proportional valves
function manifold

Genie Z-45/22

7 - 45

Service Manual - First Edition

Section 7 - Repair Procedures

Fuel and Hydraulic Tanks

6 Remove the mounting fasteners from the
bottom of the reservoir.

12-1
Hydraulic Reservoir
The primary functions of the hydraulic reservoir
are to cool, clean and deaerate the hydraulic fluid
during operation. This reservoir has a 25 gallon
(94.5 liters) capacity and an oil level gauge with
temperature indicator. It utilizes internal suction
strainers for the pump supply suction lines and
has an external return line filter.

How to Remove the Hydraulic

Reservoir
The work area and surfaces
where this procedure will be
performed must be clean and free
of debris that could get into the
hydraulic system and cause
severe component damage.
1 Raise the primary boom until it is horizontal to
access the anchor hook.

7 Use an appropriate lifting device to remove the

reservoir from the machine.
Always use pipe thread sealant
when re-installing the drain plug.
Use only Dexron II equivalent
hydraulic fluid.
Be sure to open the two hydraulic
tank valves and prime the pump
after installing the pump.

How to Prime the Pump

1 Gasoline/LPG models: Disconnect the ignition
coil wire and isolate it from ground.
Diesel models: Disconnect the wiring to the
injection pump fuel-on solenoid
2 Crank the engine with the starter motor for 15
seconds.

2 Close the two hydraulic tank valves located at

the main pump.

open

closed

3 Completely drain the oil from the reservoir by

removing the drain plug located in the bottom
front of reservoir.
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

Service Manual - First Edition

Section 7 - Repair Procedures

FUEL AND HYDRAULIC TANKS

12-2
Fuel Tank
How to Remove the Fuel Tank
Engine fuels are combustible.
Remove the fuel tank in an open,
well-ventilated area away from
heaters, sparks, flames and
lighted tobacco. Always have an
approved fire extinguisher within
easy reach.
Explosion hazard. When
transferring fuel, connect a
grounding wire between the
machine and pump or container.
1 Raise the elevate assembly enough to access
the back of the fuel tank.
2 Turn the manual fuel shutoff valve to the closed
position.
3 Gasoline/LPG models: Disconnect the
electrical collectors from the fuel shutoff
solenoid. Disconnect, drain and plug the fuel
hose.
Diesel models: Disconnect, drain and plug the
supply and return fuel hoses. Cap the fuel
return fitting on the fuel tank.
4 Remove the tank anchor hook from the back of
the 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

Service Manual - First Edition

Section 7 - Repair Procedures

Turntable Rotation Components

13-1
Rotation Hydraulic Motor

13-2
Rotation Bearing and Worm Drive

The rotation hydraulic motor is the only

serviceable component of the turntable rotation
assembly. The worm gear may not be removed
from the housing. In order to remove the housing,
the turntable has to be removed.

How to Remove the Rotation

Bearing or Worm Drive

How to Remove the Turntable

Rotation Motor

The turntable and all components above it must be

removed prior to removing the rotation bearing or
worm drive.
This procedure requires specific
repair skills, lifting equipment and
a suitable workshop. Attempting
this procedure without these skills
and tools may result in death or
serious injury and significant
component damage. Dealer
service is required.

1 Remove the hydraulic hoses attached to the

turntable rotation motor and plug them.
Bodily injury hazard. Spraying
hydraulic oil can perforate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.
2 Remove the turntable rotation motor mounting
bolts, then remove the motor.

Be sure that the chassis is level.

1 Remove the platform. See 2-1, How to Remove
the Platform.
2 Remove the primary boom. See 3-2, How to
Remove the Primary Boom.

Do not allow the turntable to

rotate until the hydraulic motor is
installed.

Crushing hazard. Do not remove

the 4x4x31 inch (78cm) support
block installed during primary
boom removal.
a

b
c

a
b
c

7 - 48

Genie Z-45/22

upper mid-pivot
4x4x31 inch block
counterweight

Part No. 29487

Service Manual - First Edition

Section 7 - Repair Procedures

TURNTABLE ROTATION COMPONENTS

3 Use an overhead crane to attach a lifting strap

to the rod-end of the primary lift cylinder. Then
raise the primary lift cylinder with the crane, to
a vertical position.

8 Disconnect the three 3/4 inch hydraulic hoses

from the main pump and plug them.
Bodily injury hazard. Spraying
hydraulic oil can perforate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.

4 Remove the pin retainer from the pivot pin at

the barrel-end of the primary lift cylinder.
5 Place a rod through the barrel-end pivot pin
and twist to remove the pin. Remove the
primary lift cylinder from the machine.

9 Disconnect the same three 3/4 inch hydraulic

hoses from the drive traction manifold and plug
them. Pull these hoses up through the turntable
and remove them from the machine.
b
a

a
b

10 Disconnect the in and return hydraulic hoses

from the steer/oscillate manifold and plug them.
Pull these hoses up through the turntable.
11 Disconnect the hydraulic hoses from the
turntable rotation motor and plug them. Pull
these hoses up through the turntable.

10 to 12 inch (30cm) rod

pivot pin

Crushing hazard. The primary lift

cylinder will fall when the barrelend pivot pin is removed if it is not
properly supported.

12 Label and then disconnect all the wiring from

the traction manifold and the steer/oscillate
manifold.
13 Disconnect and remove the oscillating axle limit
switches from the oscillation cylinder.

6 Raise the elevate assembly. Remove the block

from the turntable counterweight and lower the
elevate assembly to the fully stowed position.
7 Close the two hydraulic tank valves located at
the main pump.

a
b

open

Part No. 29487

Oscillating axle limit switch

a
limit switch
b
oscillate lock-out wedge

closed

Genie Z-45/22

7 - 49

Service Manual - First Edition

Section 7 - Repair Procedures

TURNTABLE ROTATION COMPONENTS

14 Disconnect and remove the drive enable limit

switch.

22 Place a 5 inch (13cm) tall block near the end of

the forks for support.

drive enable limit switch

15 Pull the wiring harness along with the limit

switches up through the turntable.

b
a
b

16 Remove the turntable end cover.

forks
block

17 Loosen the lug nuts on both steer tires. Do not

remove them.

23 Raise the forks up against the turntable. Do not

lift. Be sure that the support block is still in its
proper location.

18 Center a lifting jack under the steering axle. Lift

the machine until the tires are just off the
ground.

24 Place a safety strap around the upper midpivot, then secure the strap to the forklift
carriage.

19 Support the chassis on blocks, then remove

both steer tires and wheel assemblies to
improve access when removing the turntable.

25 Remove the turntable mounting bolts.

20 Prepare a forklift with a minimum rating of

18,000 pounds (8165kg) by spreading the forks
to an inside width of 3 feet (0.9m).
21 Position the forklift at the counterweight end of
the turntable. Center the forks underneath the
turntable and above the chassis. Do not lift.

26 Carefully lift the turntable off the chassis. Set

the turntable on blocks for support.
27 Place reference marks on the chassis to note
the position of the worm drive housing for
proper re-alignment during re-installation.
28 Remove the fasteners from the worm drive,
then remove the worm drive.
29 Center the forklift forks under the chassis
counterweight for support.
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

Service Manual - First Edition

Section 7 - Repair Procedures

TURNTABLE ROTATION COMPONENTS

How to Install the Rotation

Bearing and Worm Drive

The rotation bearing is a structural component. It

attaches the chassis to the turntable. The
turntable is bolted to the inner race, with the worm
gear housing sandwiched in-between. This
housing has to be exactly positioned to provide the
correct gear lash between the worm gear and the
ring gear. The outside bearing race is bolted to the
chassis from the underside.
This procedure requires specific
repair skills, lifting equipment and
a suitable workshop. Attempting
this procedure without these skills
and tools may result in death or
serious injury and significant
component damage. Dealer
service is required.
If a repair requires that the
turntable be removed from the
chassis, installing a new rotation
bearing is recommended.
Consider the service life of the
rotation bearing before installing a
used bearing.

e
d
a

c
b

a
b
c
d
e
f

"O" mark
outer bearing
inner bearing
dowel
red mark
rotation stop block

3 Install the mounting fasteners from underneath

the chassis. Use a torque wrench to tighten the
fasteners in sequence to specifications.

1 Position the rotation bearing on the chassis.

10

15

13

2 Locate the red mark on the outside bearing

race. Align the mark with the rotation stop
block on the chassis.

12

18

17

11
5

8
16

14
2

Specifications - torque

Part No. 29487

First rotation

95 foot pounds
129 Newton meters

Second rotation

190 foot pounds

258 Newton meters

Genie Z-45/22

7 - 51

Service Manual - First Edition

Section 7 - Repair Procedures

TURNTABLE ROTATION COMPONENTS

4 Locate the 0 mark stamped in the outside

bearing and the dowel on the inside bearing.
5 Position the inside bearing dowel 90 degrees
counterclockwise from the 0 mark on the
outside bearing.

15 Install the turntable mounting fasteners. Use a

torque wrench to tighten the fasteners in
sequence to specifications.
6

20

22

13
7

16

6 Install a grease fitting on the inside bearing and

apply grease until it comes out of the inner
seal.

12

11

7 Apply grease to 10 gear teeth on each side of

the 0 mark on the outside bearing.

23

17

15

8 Center the worm drive over the 0 mark on the

outside bearing and install the two 5/16 inch
fasteners. Hand tighten the bolts.
9 Push the worm drive towards the rotation
bearing to be as close as possible.

18

24

14

5
21

10

19

Specifications - torque

10 Position a dial indicator to measure the worm

drive in relation to the ring gear. Pull the worm
drive away from the rotate bearing 0.035
inches (0.889mm) 0.020 inches (0.508mm).

First rotation

95 foot pounds
129 Newton meters

Second rotation

190 foot pounds

258 Newton meters

11 Tighten the two 5/16 fasteners. Observe the

dial indicator to be sure that the worm drive
does not move.
12 Locate the 1 inch hex head on the end of the
worm gear housing. Turn the hex head to
rotate the worm drive until it is positioned within
the original reference marks on the chassis.

After re-assembly, the turntable

should swing smoothly without
jerking or grinding.

13 Position the turntable so that the flat side of the

turntable is parallel with the worm drive gear.
14 While lowering the turntable onto the chassis,
be sure that the milled area on the bottom
surface of the turntable does not contact the
top of the worm drive gear housing. 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

Service Manual - First Edition

Section 7 - Repair Procedures

2WD Steering Axle Components

7 Place a second jack under the yoke/hub
assembly.

14-1
Yoke and Hub

8 Use a soft metal drift to drive the king pin down

and out.

How to Remove the Yoke/Hub

Assembly

Crushing hazard. The yoke/hub

assembly will fall when the king
pin is removed if it is not properly
supported.

1 Remove the cotter pin, and the clevis pin from

both the steering cylinder and tie rod weldment.

Always use a new cotter pin when

re-installing a clevis pin.

How to Remove the Hub and

Bearing
a
h

a
b
c
d
e
f
g
h

1 Loosen the wheel lug nuts. Do not remove

them.
2 Place a lifting jack under the steering axle.
3 Raise the machine and place blocks under the
chassis.
4 Remove the lug nuts, then the tire and wheel
assembly.
5 Remove the dust cap, cotter pin and slotted
nut.

axle
pin retainer
king pin
yoke
hub
cotter and clevis pin
steering cylinder
tie rod

6 Pull the hub from the spindle. The washer and

outer bearing should fall loose from the hub.
7 Place the hub on a flat surface and gently pry
the bearing seal out of the hub. Remove the
rear bearing.

2 Break loose the wheel lug nuts. Do not remove

them.
3 Block the non-steering wheels and place a
lifting jack under the steering axle.
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

Service Manual - First Edition

Section 7 - Repair Procedures

2WD STEERING AXLE COMPONENTS

How to Install the Hub and

Bearing

14-2
Steering Cylinders

1 Be sure that the bearing is packed with grease.

2 Place the large inner bearing into the rear of
the hub.
3 Press the bearing seal into the hub. Rest the
seal on the hub, then press the seal evenly into
the hub until it is flush.
4 Slide the hub onto the yoke spindle.
Component damage hazard. Do
not apply excessive force or
damage to the lip of the seal may
result.

How to Remove a Steering

Cylinder
There are two identical steering cylinders that
work in parallel. They are part of the same
hydraulic circuit, but move in opposite directions.
The tie rod maintains equal movement of the tires.
Bushings are used at both ends of each steering
cylinder clevis.
1 Disconnect the hydraulic hoses from the
steering cylinder and plug them.
Bodily injury hazard. Spraying
hydraulic oil can perforate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.

5 Be sure that the outer bearing is packed with

grease, and place it into the hub.
6 Install the washer and slotted nut.
7 Tighten the slotted nut to 35 foot-pounds
(47Nm).
8 Loosen the slotted nut and then re-tighten to
8 foot-pounds (11Nm).

2 Remove the cotter pin, then the clevis pin from

each end of the steering cylinder.

9 Install a new cotter pin. Bend the pin to lock it

in.

3 Remove the steering cylinder.

10 Install the dust cap, then the tire and wheel

assembly. Torque the wheel lug nuts to
125 foot-pounds (169Nm).

7 - 54

Genie Z-45/22

Always use a new cotter pin when

re-installing a clevis pin.

Part No. 29487

Service Manual - First Edition

Section 7 - Repair Procedures

2WD STEERING AXLE COMPONENTS

5 Remove the cotter pin, then remove the clevis

pin from the adjustable end of the tie rod.

14-3
Tie Rod

6 Slide the tie rod off the yoke and adjust it by

turning the end.

How to Remove the Tie Rod

Weldment

One half turn on the adjustable

end equals a 3/16 inch (5mm)
change in the front to rear
measurement.

1 Remove the cotter pins, then the clevis pins

from the ends of the tie rod.
2 Remove the tie rod weldment.
Always use a new cotter pin when
re-installing a clevis pin.

How to Perform the

Tie Rod Toe-in Adjustment
Perform this procedure on a
firm level surface. Block the
non-steering tires and be sure
that the machine is in the fully
stowed position.

7 Slide the tie rod onto the yoke. Install the clevis
pin, then a new cotter pin.
8 Tighten the jam nut against the tie rod.
9 Lower the machine and recheck the front
and back measurements (step 2). If further
adjustment is needed, repeat steps 3
through 8.
Specifications
Tie rod adjustment

1/4 inch (0.635mm) toe-in to

1/4 inch (0.635mm) toe-out

1 Measure 15 inches (38cm) up from the ground

on the front and rear of each steer tire and
make a reference mark at the center of the tire.
2 Measure the distance from the reference points
on each tire: 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

Service Manual - First Edition

Section 7 - Repair Procedures

4WD Steering Axle Components

2 Disconnect the hydraulic hoses from the wheel
motor and plug them. Cap the wheel motor
hydraulic fittings.

15-1
Yoke and Hub

Bodily injury hazard. Spraying

hydraulic oil can perforate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.

How to Remove the Yoke and Hub

The yoke installation utilizes bushings and a thrust
washer that require periodic replacement
depending upon the application. The yoke must be
removed before the torque hub can be removed.
The wheel motor is an integral part of the torque
hub.
1 Remove the cotter pin, then the clevis pin from
both the steering cylinder and the tie rod
weldment.

3 Loosen the wheel lug nuts. Do not remove

them.
4 Block the non-steering wheels, and then center
a lifting jack under the steering axle.
5 Raise the machine 6 inches (15cm) and place
blocks under the chassis.
6 Remove the lug nuts, then the tire and wheel
assembly.

7 Remove the pin retainer from the king pin.

8 Place a block between the oscillate cylinder

lock-out wedge and the chassis on the same
side as the yoke/torque hub being serviced.

a
b
c
d
e
f
g
h

axle
pin retainer
king pin
yoke
torque hub
cotter and clevis pin
steering cylinder
tie rod
f

a
b
c
d
e
f

7 - 56

Genie Z-45/22

block
torque hub
yoke
axle
lock-out wedge
chassis

Part No. 29487

Service Manual - First Edition

Section 7 - Repair Procedures

4WD STEERING AXLE COMPONENTS

9 Attach a strap from a lifting device to the yoke/

torque hub assembly and support it.
10 Use a soft metal drift to drive the king pin down
and out.
Crushing hazard. The yoke/torque
hub assembly will fall when the
king pin is removed if it is not
properly supported.
11 Place the yoke/torque hub assembly on a flat
surface with the torque hub down. Remove the
bolts that secure the yoke to the torque hub.
Specifications
Lug nut torque

15-3
Tie Rod
How to Remove the Tie Rod
Weldment
This procedure is the same as the 2WD
procedure. See repair procedure 14-3, How to
Remove the Tie Rod Weldment.

How to Perform the Tie Rod

Toe-in Adjustment
This procedure is the same as the 2WD
procedure. See repair procedure 14-3, How to
Perform the Tie Rod Toe-in Adjustment.

125 foot-pounds
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

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Service Manual - First Edition

Section 7 - Repair Procedures

Oscillating Axle Components

16-1
Oscillating Axle Lock-out Cylinder
The oscillating axle lock-out cylinder extends the
lock-out wedges between the chassis and the axle
when the boom is raised above the drive limit
switch. When the lock-out wedges are fully
extended, the oscillation lock-out limit switches
release and allow the primary boom to continue to
raise above the drive limit switch.

How To Remove The Oscillating

Axle Lock-out Cylinder
The oscillating axle lock-out cylinder is held in
place by the same pin that retains the axle.
Therefore, the axle must be removed as part of
this procedure.

from the oscillating axle lock-out cylinder.

3 Block the non-steering wheels, then center a
jack under the oscillating axle and lift the
machine 6 inches (15cm).
4 Support the raised machine with blocks, then
carefully lower the chassis onto the blocks.
Leave the jack under the axle to support it. Do
not lift.
Crushing hazard. If the jack is not
centered, the axle may tip when
the pivot pin is removed.
5 Remove the pin retainer from the axle pivot pin.
Use a soft metal drift to remove the axle pivot
pin.
6 Remove the oscillate cylinder.

This procedure requires specific

repair skills, lifting equipment and
a suitable workshop. Attempting
this procedure without these skills
and tools may result in death or
serious injury and significant
component damage. Dealer
service is strongly recommended.
Perform this procedure on a firm
level surface.
1 Disconnect and plug the oscillating axle lockout cylinder hydraulic hoses. Disconnect and
plug the steer and accumulator hoses from the
steer-oscillate manifold to provide clearance for
pin removal.
Bodily injury hazard. Spraying
hydraulic oil can perforate and
burn skin. 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

Service Manual - First Edition

Section 7 - Repair Procedures

Steer and Oscillate Manifold

17-1
Steer and Oscillate Manifold Components
Index
No.

Description

Schematic
Item

3 position 4 way DO1 valve .............. F ........... Steering ............................................. 30-35 in-lbs / 3-4 Nm

Pilot operated unloader valve,

1900 psi / (131 bar) ........................... C ........... Sequencing ....................................... 10-12 ft-lbs / 14-16 Nm

Sensing valve .................................... B ........... Differential sensing ........................... 10-12 ft-lbs / 14-16 Nm

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

Function

Torque

1
6

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Service Manual - First Edition

Section 7 - Repair Procedures

STEER AND OSCILLATE MANIFOLD

2 Connect a 0 to 3000 psi (0 to 206 bar) pressure

gauge to the diagnostic nipple on the function
manifold.

Plug Torque Specifications

Description

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

3 Manually hold down the drive limit switch.

When the oscillate cylinder fully retracts, the
pressure will spike. Note the maximum
pressure reading. Do not release the drive limit
switch.
4 Release the drive limit switch. When the
oscillate cylinder fully extends, the pressure will
spike. Note the maximum pressure reading.
5 Hold the unloader valve and remove the cap
(index 2).
6 Adjust the internal hex socket by turning it
clockwise to increase the pressure or
counterclockwise to decrease the pressure.
Then reinstall the relief valve cap.

17-2
Valve Adjustments

7 Manually hold down the drive limit switch and

recheck the valve pressure.

How to Adjust the Sequencing

Unloader Valve
Bodily injury hazard. Spraying
hydraulic oil can perforate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.

Specifications
Unloader valve

1900 psi /
131 bar

1 Start the engine and raise the primary boom

above the drive limit switch. Do not lift the
primary boom above the secondary boom.

a
a

7 - 60

drive limit switch

Genie Z-45/22

Part No. 29487

Service Manual - First Edition

Section 7 - Repair Procedures

Non-steering Axle Components

18-1
Drive Motor

18-2
Torque Hub

Repairs to the motor should only

be performed by an authorized
Sundstrand-Sauer dealer.

How to Remove a Drive Torque

Hub
The drive motor and brake must be removed in
order to access the torque hub mounting bolts.

How to Remove a Drive Motor

A drive motor can only be removed from the inside
of the chassis. Access on older machines is even
more restricted. The brake and motor must be
removed together and then separated for repair.
The work area and surfaces
where this procedure will be
performed must be clean and free
of debris that could get into the
hydraulic system and cause
severe component damage.
Dealer service is recommended.
1 Disconnect the hydraulic hoses from the drive
motor and plug them.
Bodily injury hazard. Spraying
hydraulic oil can perforate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.

1 Remove the drive motor and brake. See 18-1,

How to Remove a Drive Motor.
2 Loosen the wheel lug nuts. Do not remove
them.
3 Center a jack under the non-steering axle.
Raise the machine and place blocks under the
chassis to support it.
4 Remove the wheel lug nuts, then the tire and
wheel assembly.
5 Place a second jack under the torque hub for
support.
6 Remove the bolts that attach the brake to the
hub.
7 Remove the bolts that attach the torque hub to
the chassis, then remove the torque hub.
Crushing hazard. The torque hub
will fall if it is not properly
supported when the mounting
bolts are removed.

2 Remove the drive motor mounting bolts.

3 Slide the drive motor shaft out of the brake and
then remove.
On older machines, the drive
motor and brake must be
removed together.

Part No. 29487

Specifications
Lug nut torque

Genie Z-45/22

125 foot-pounds
169 Newton meters

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Service Manual - First Edition

Section 7 - Repair Procedures

2WD Drive Manifold

19-1
2WD Drive Manifold Components
Index
No.

Description

Schematic
Item

Check valve ................................. M .................... Brake check .......................... 25-30 ft-lbs / 34-41 Nm

2 position 3 way valve ................. O .................... Brake release ........................ 8-10 ft-lbs / 11-14 Nm

2 position 3 way valve ................. N ..................... 2-Speed wheel motors,

(energized in high range to
destroke the rear motor
swash plates ......................... 8-10 ft-lbs / 11-14 Nm

Orifice 0.036 in (0.914mm) ......... P ..................... Motor shift / brake release circuit

Function

Torque

Pilot to open check valve ............ E ..................... Right check in forward .......... 85-90 ft-lbs / 115-122 Nm

Pilot to open check valve ............ G .................... Right check in reverse .......... 85-90 ft-lbs / 115-122 Nm

Shuttle valve 3 position 3 way .... K ..................... Low pressure flow path for
brake release and 2-speed
motor shift ............................. 15-18 ft-lbs / 20-24 Nm

Pilot to open check valve ............ D ..................... Left check in reverse ............. 85-90 ft-lbs / 115-122 Nm

Pilot to open check valve ............ B ..................... Left check in forward ............. 85-90 ft-lbs / 115-122 Nm

10

2 position 3 way valve ................. J ..................... Energized in high range to

pilot open check valves
5,6, 8 & 9 to bypass flow
regulators and allow full
flow to front wheel motors ..... 8-10 ft-lbs / 11-14 Nm

11

Shuttle valve 2 position 3 way ..... I ..................... High pressure flow path for
flow regulator bypass ............ 10-13 ft-lbs / 14-18 Nm

12

Flow regulator valve .................... A ..................... Left flow control in forward .... 10-12 ft-lbs / 14-16 Nm

13

Flow regulator valve .................... C ..................... Left flow control in reverse .... 10-12 ft-lbs / 14-16 Nm

14

Relief valve, 320 psi (22 bar) ...... L ..................... Charge pressure ................... 10-12 ft-lbs / 14-16 Nm

15

Flow regulator valve .................... H ..................... Right flow control in reverse . 10-12 ft-lbs / 14-16 Nm

16

Flow regulator valve .................... F ..................... Right flow control in forward . 10-12 ft-lbs / 14-16 Nm

Plug Torque Specifications

Description

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

7 - 62

Genie Z-45/22

Part No. 29487

Service Manual - First Edition

Section 7 - Repair Procedures

2WD DRIVE MANIFOLD

10

16

15
14

13
12

11

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Service Manual - First Edition

Section 7 - Repair Procedures

2WD DRIVE MANIFOLD

19-2
Valve Adjustments
How to Adjust the Charge
Pressure Relief Valve
1 Connect a 0 to 600 psi (0 to 41 bar) pressure
gauge in between one of the medium pressure
hydraulic hoses and the medium pressure
hydraulic oil filter.
Bodily injury hazard. Spraying
hydraulic oil can perforate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.
2 Start the engine from the platform controls.
3 Drive the machine in either direction and
observe the pressure reading on the pressure
gauge.
4 Turn the engine off. Hold the relief valve and
remove the cap (index 14).
5 Adjust the internal hex socket. Turn it clockwise
to increase the pressure or counterclockwise to
decrease the pressure. Then reinstall the valve
cap.
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

7 - 64

320 psi / 22 bar

Genie Z-45/22

Part No. 29487

Service Manual - First Edition

Section 7 - Repair Procedures

2WD DRIVE MANIFOLD

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Service Manual - First Edition

Section 7 - Repair Procedures

4WD Drive Manifold

20-1
4WD Drive Manifold Components
Index
No.

Description

Check valve ........................... W ................... Brake check ............................... 25-30 ft-lbs / 34-41 Nm

2 position 3 way valve ........... S .................... Brake release ............................. 8-10 ft-lbs / 11-14 Nm

2 position 3 way valve ........... R .................... 2-speed wheel motors

(energized in high range to
destroke the rear motor
swash plates) ............................. 8-10 ft-lbs / 11-14 Nm

Check valve ........................... K .................... RR check in forward ................... 35-40 ft-lbs / 47-54 Nm

Orifice 0.025 in (0.635mm) .... X .................... Motor shift / brake release circuit

Check valve ........................... L .................... RR check in reverse ................... 35-40 ft-lbs / 47-54 Nm

Relief valve, 320 psi (22 bar) . V .................... Charge pressure ........................ 10-12 ft-lbs / 14-16 Nm

Shuttle valve 3-position 3 way U .................... Low pressure flow path for
brake release and
2 speed motor shift .................... 15-18 ft-lbs / 20-24 Nm

Pilot to open check valve ....... O ................... RF check in forward ................... 85-90 ft-lbs / 115-122 Nm

10

Pilot to open check valve ....... P .................... RF check in reverse ................... 85-90 ft-lbs / 115-122 Nm

11

Check valve ........................... J .................... LR check in reverse ................... 35-40 ft-lbs / 47-54 Nm

12

Check valve ........................... I ..................... LR check in forward ................... 35-40 ft-lbs / 47-54 Nm

13

Pilot to open check valve ....... N .................... LF check in reverse .................... 85-90 ft-lbs / 115-122 Nm

14

Pilot to open check valve ....... M ................... LF check in forward ................... 85-90 ft-lbs / 115-122 Nm

15

2 position 3 way valve ........... Q ................... Energized in high range to

pilot open check valves
9, 10, 13 & 14 to bypass flow
regulators and allow full
flow to front wheel motors .......... 8-10 ft-lbs / 11-14 Nm

16

Shuttle valve 2 position 3 way T .................... High pressure flow path for
flow regulator bypass ................. 10-13 ft-lbs / 14-18 Nm

17

Flow regulator valve ............... D .................... LR flow control in reverse .......... 10-12 ft-lbs / 14-16 Nm

18

Flow regulator valve ............... B .................... LR flow control in forward .......... 10-12 ft-lbs / 14-16 Nm

19

Flow regulator valve ............... H .................... RR flow control in reverse .......... 10-12 ft-lbs / 14-16 Nm

20

Flow regulator valve ............... F .................... RR flow control in forward .......... 10-12 ft-lbs / 14-16 Nm

21

Flow regulator valve ............... A .................... LF flow control in forward ........... 10-12 ft-lbs / 14-16 Nm

22

Flow regulator valve ............... C .................... LF flow control in reverse ........... 10-12 ft-lbs / 14-16 Nm

23

Flow regulator valve ............... G ................... RF flow control in reverse .......... 10-12 ft-lbs / 14-16 Nm

24

Flow regulator valve ............... E .................... RF flow control in forward .......... 10-12 ft-lbs / 14-16 Nm

7 - 66

Schematic
Item

Function

Genie Z-45/22

Torque

Part No. 29487

Service Manual - First Edition

Section 7 - Repair Procedures

4WD DRIVE MANIFOLD

10

11

12

13

14

24

23
22
21
15

20

19

18

Part No. 29487

17

16

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Service Manual - First Edition

Section 7 - Repair Procedures

4WD DRIVE MANIFOLD

Plug Torque Specifications

Description

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

20-2
Valve Adjustments
How to Adjust the Charge
Pressure Relief Valve
1 Connect a 0 to 600 psi (0 to 41 bar) pressure
gauge in between one of the medium pressure
hydraulic hoses and the medium pressure
hydraulic oil filter.
Bodily injury hazard. Spraying
hydraulic oil can perforate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.
2 Start the engine from the platform controls.
3 Drive the machine in either direction and
observe the pressure reading on the pressure
gauge.
4 Turn the engine off. Hold the relief valve and
remove the cap.
5 Adjust the internal hex socket. Turn it clockwise
to increase the pressure or counterclockwise to
decrease the pressure. Then reinstall the valve
cap.
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

7 - 68

Genie Z-45/22

320 psi / 22 bar

Part No. 29487