Second EditionSecond PrintingPart No. 82596Operator’s Manualwith Maintenance InformationBi-Energy Power

Genie Z-45/25 Bi-Energy Operators Manual With Maintenance Information

Z-45/25

safety rules

personal safety

April

performance specifications

engine specifications

hydraulic specifications

about this section

maintenance inspection report

Z-30/20N (RJ

Z-51/30J

Z-34/22 BE

workplace inspection

specifications

hydraulic hose and fitting torque specifications

electrical system

machine controls

optional equipment

wear pads

fault codes

platform controls

electrical symbols legend

hydraulic symbols legend

repair procedures

foot switch

platform components

platform leveling slave cylinder

platform rotator

jib boom components, z-45/25j models

jib boom lift cylinder

jib boom / platform rotate manifold components, z-45/25j models

primary boom components

primary boom

boom lift cylinder

boom extension cylinder

secondary boom components

secondary boom lift cylinders

turntable covers

perkins 104-22 engine

ford lrg-425 efi engine

control relays

hydraulic pumps

drive pump

function manifold components

turntable rotation manifold components

directional valve manifold components

fuel and hydraulic tanks

turntable rotation components

yoke and hub

tie rod

oscillating axle components

non-steering axle components

drive hub

September

Specifications

Performance Specifications

Hydraulic Component Specifications

Machine Torque Specifications

Hydraulic Hose and Fitting Torque Specifications

Torque Procedure

Section 3 Repair Procedures

Platform Controls

Joysticks

How to Adjust the Joystick Max-out Setting

How to Adjust the Joystick Ramp Rate Setting

How to Adjust the Joystick Threshold Setting

Platform Components

How to Bleed the Slave Cylinder

Platform Rotator

Platform Overload System

Jib Boom Components

Jib Boom Lift Cylinder

Primary Boom Components

How to Remove the Cable Track, Z-45/25J

How to Repair the Primary Boom Cable Track

How to Disassemble the Primary Boom

Primary Boom Lift Cylinder

Primary Boom Extension Cylinder

Platform Leveling Master Cylinder

Secondary Boom Components

Secondary Boom

Secondary Boom Lift Cylinders

Engines

How to Install the Flex Plate

How to install the Pump and Bell Housing Assembly

Ford MSG-425 Engine Fault Codes

Hydraulic Pumps

Drive Pump

How to Prime the Pump

Manifolds

Valve Adjustments - Function Manifold

How to Adjust the Secondary Boom Down Relief Valve

Jib Boom / Platform Rotate Manifold Components

Turntable Rotation Manifold Components

Directional Valve Manifold Components

How to Set Up the Directional Valve Linkage

Traction Manifold Components, 2WD

Valve Adjustments, 2WD Traction Manifold

Traction Manifold Components, 4WD

Valve Adjustments, 4WD Traction Manifold

Hydraulic Generator Manifold Components, 2.2kW

Valve Coils

Turntable Rotation Components

Axle Components

Oscillating Axle Cylinders

Section 4 Fault Codes

Control System Fault Codes

Fault Code Display - Deutz and Perkins Models

Fault Code Display - Flashing and Solid LED's - Deutz D 2.9 L4 and Perkins 404F-22 Models

Soft Key Functions and Icons Deutz D 2.9 L4 and Perkins 404F-22 Models

Main Menu Structure - Deutz D 2.9 L4 Models

Main Menu Structure - Perkins 404F-22 Models

Deutz D 2.9 L4 Engine Fault Codes

Perkins 404F-22 Engine Fault Codes

Section 5 Schematics

Electrical Symbol Legend

Hydraulic Symbols Legend

Electrical Component and Wire Color Legends

Ford Engine Relay Layout

Engine Relay Layout - Deutz D 2.9 L4 and Perkins 404F-22

Ford MSG-425 EFI Engine Wire Harness

Deutz D 2.9 L4 Engine Wire Harness

Perkins 404F-22 Engine Wire Harness

Electrical Schematic, Options (All Models)

Ground Control Box Terminal Strip Wiring Diagram, Options

Platform Control Box Wiring Diagram, Options

Wiring Diagram - Battery, Hydraulic Oil and Engine Oil Heater Options

Wiring Diagram, 2.2kW Hydraulic Generator

Hydraulic Schematics

Hydraulic Schematic, 2WD Models

Hydraulic Schematic, 4WD Models

Electrical Schematic, Ford MSG-425 EFI Models (ANSI/CSA)

Ground Control Box Terminal Strip Wiring Diagram Ford MSG-425 EFI Models (ANSI/CSA)

Ground Control Box Switch Panel Wiring Diagram Ford MSG-425 EFI Models (ANSI/CSA)

Platform Control Box Wiring Diagram Ford MSG-425 EFI Models (ANSI/CSA)

Ground Control Box Terminal Strip Wiring Diagram - Deutz D2011 L03i Perkins 404D-22 Models (ANSI/CSA)

Ground Control Box Switch Panel Wiring Diagram - Deutz D2011 L03i Perkins 404D-22 Models (ANSI/CSA)

Platform Control Box Wiring Diagram - Deutz D2011 L03i Perkins 404D-22 Models (ANSI/CSA)

Platform Control Box Switch Panel Wiring Diagram - Deutz D2011 L03i Perkins 404D-22 Models (ANSI/CSA)

Introduction

Symbol and Hazard Pictorial Definitions

General Safety

Personal Safety

Work Area Safety

Legend

Controls

Inspections

Operating Instructions

Transport and Lifting Instructions

Maintenance

Safety

Pre-operation Inspection

Function Tests

Workplace Inspection

Transport Instructions

Decals

Symbol and Hazard Pictorials Definitions

Z-45/25 • Z-45/25J Part No

A Machine Specifications

A Hydraulic Specifications

A Hydraulic Hose and Fitting Torque Specifications

Pre-delivery Preparation

Maintenance Inspection Report

A-1 Perform Pre-operation Inspection

A-3 Check for Hydraulic Leaks

A-5 Perform Function Tests

A-8 Perform Engine Maintenance

A-10 Perform Engine Maintenance

A-12 Perform Engine Maintenance

B-1 Check the Radiator

B-3 Check the Batteries

B-4 Inspect the Electrical Wiring

B-6 Confirm the Proper Brake Configuration

B-8 Check and Adjust the Engine RPM

B-10 Test the Platform Self-leveling

B-12 Test the Drive Brakes

B-13 Test the Drive Speed - Stowed Position

B-15 Test the Alarm Package (if equipped)

B-16 Test the Turntable Rotation Stop

B-18 Replace the Hydraulic Tank Return Filter

B-20 Perform Engine Maintenance

C-1 Perform Engine Maintenance

C-4 Perform Engine Maintenance

D-1 Check the Primary Boom Wear Pads

D-3 Check the Free-wheel Configuration

D-4 Replace the Drive Hub Oil

D-6 Perform Engine Maintenance

E-1 Test or Replace the Hydraulic Oil

E-2 Perform Engine Maintenance

E-3 Grease the Steer Axle Wheel Bearings

Controllers

Platform Leveling Slave Cylinder

Jib Boom

Cable Track

Primary Boom

Timing Adjustment

Generator Pulley

Generator Belts