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Z- 45 22
Service
Manual
Introduction
Important
Read, understand and obey the safety rules and
operating instructions in the Genie Z-45/22
Operator's Manual before attempting any
maintenance or repair procedure.
This service manual covers the Genie Z-45/22
2WD and 4WD models introduced in 1994.
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 Europe
Telephone (44) 0636-813943
Fax (44) 0636-815270
ii
Genie Z-45/22
Important
Verify Correct Manual
Do not read any further until you
have verified that this is the
correct manual for this machine.
Contact Genie Industries if you
have any questions.
This manual covers the Genie
Z-45/22 2WD and 4WD models produced from
May 1994, starting with serial number
Z-45-001523.
Genie Z-45/22
iii
iv
Genie Z-45/22
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.
Genie Z-45/22
SAFETY RULES
Personal Safety
Workplace Safety
vi
Genie Z-45/22
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
Deutz F3L Engine Specifications .............................................................................. 2 - 7
Section Three
Section Four
A-1
A-2
A-3
A-4
A-5
A-6
A-7
A-8
A-9
Genie Z-45/22
vii
TABLE OF CONTENTS
Section Four
B-2
B-3
Check the Oil Cooler and Cooling Fins - Deutz Diesel Models ..................... 4 - 11
B-4
B-5
B-6
B-7
B-8
Inspect the Tires and Wheels (including lug nut torque) ............................... 4 - 14
B-9
iix
Genie Z-45/22
TABLE OF CONTENTS
Section Four
C-2
C-3
C-4
C-5
C-6
C-7
C-8
C-9
D-1
D-2
D-3
D-4
D-5
D-6
D-7
Check the Fuel Injection Pumps and Injectors - Deutz Diesel Models .......... 4 - 41
D-8
D-9
Genie Z-45/22
ix
TABLE OF CONTENTS
Section Five
Engine Cranks Over But Will Not Start - Gasoline/LPG Models ..................... 5 - 5
Engine Cranks Over But Will Not Start - Deutz Diesel Models ..................... 5 - 12
10
11
All Lift and Steer Functions Inoperative, Drive Functions Operational .......... 5 - 27
12
13
14
15
16
17
18
19
20
21
22
23
24
25
Genie Z-45/22
TABLE OF CONTENTS
Section Five
Section Six
27
28
29
30
31
All Drive Functions Inoperative, All Other Functions Operate Normally ........ 5 - 53
32
33
34
35
36
37
38
39
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
Platform Control Box Legend - Diesel Models ........................................................ 6 - 11
Hydraulic Symbols Legend ..................................................................................... 6 - 12
2WD Hydraulic Schematic ...................................................................................... 6 - 13
4WD Hydraulic Schematic ...................................................................................... 6 - 14
Genie Z-45/22
xi
TABLE OF CONTENTS
Section Seven
Repair Procedures
Introduction ............................................................................................................... 7 - 1
Platform Controls
1-1
1-2
1-3
1-4
Resistors ......................................................................................................... 7 - 8
1-5
Platform Components
2-1
Platform ........................................................................................................ 7 - 10
2-2
2-3
3-2
3-3
3-4
3-5
4-2
Turntable Covers
5-1
6-2
xii
Genie Z-45/22
TABLE OF CONTENTS
Section Seven
7-3
7-4
7-5
7-6
7-7
7-8
Ground Controls
8-1
8-2
8-3
8-4
Resistors ....................................................................................................... 7 - 35
8-5
Hydraulic Pumps
9-1
9-2
Function Manifold
10-1 Function Manifold Components .................................................................... 7 - 40
10-2 Valve Adjustments ........................................................................................ 7 - 42
Fuel and Hydraulic Tanks
11-1 Hydraulic Tank .............................................................................................. 7 - 44
11-2 Fuel Tank ...................................................................................................... 7 - 45
Turntable Rotation Components
12-1 Rotation Hydraulic Motor .............................................................................. 7 - 46
12-2 Rotation Bearing and Worm Drive ................................................................ 7 - 46
2WD Steering Axle Components
13-1 Yoke and Hub ............................................................................................... 7 - 51
13-2 Steering Cylinders ........................................................................................ 7 - 52
Genie Z-45/22
iivx
TABLE OF CONTENTS
Section Seven
ivx
Genie Z-45/22
Section 2 - Specifications
Specifications
Machine Specifications
Stowed dimension
Length
Width
Rough terrain
Industrial
Height
Weight
Ground clearance
2WD
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
Wheel diameter
17.5 inches
14.5 inches
Wheel width
10.5 inches
7 inches
9 @ 5/8-18
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
35.8 inches
91cm
28 inches
71cm
40 psi
2.76 bar
28 psi
1.93 bar
100 psi
6.89 bar
15 gallons
56.8 liters
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
Tire size
Tire ply rating
Tire contact area
Overall tire diameter
6 ft
182.8cm
6 ft
182.8cm
30 in
76.2cm
30 in
76.2cm
45 ft
13.72m
45 ft
13.72m
23 ft
7m
23 ft
7m
21 ft 7 in
6.58m
21 ft 7 in
6.58m
1 inch
2.54cm
none
6 ft 3 in
190.5cm
6 ft 3 in
190.5cm
14 ft 4 in
4.37m
14 ft 9 in
4.49m
7 ft
2.13m
6 ft 8 in
2.03m
Turntable rotation
359
359
Platform rotation
180
180
Width
Industrial
Platform dimensions
Length
Rough terrain
Tire pressure
2WD
4WD
Operational dimensions
Maximum platform height
Maximum horizontal reach
Maximum up-and-over
clearance
Maximum turntable tailswing
Wheelbase
Fluid capacities
Fuel tank
Propane tank
Genie Z-45/22
2-1
Section 2 - Specifications
SPECIFICATIONS
Hydraulic Specifications
Performance Specifications
Drive speeds, maximum
2WD
4WD
5.0 mph
8.0km/h
4.8 mph
7.7km/h
1.1 mph
1.8km/h
or 5 feet
in 3 sec.
0.9 mph
1.4km/h
or 4 feet
in 3 sec.
Gradeability (stowed)
30%
40%
Hydraulic fluid
Dexron II equivalent
Drive pump
Type
Displacement
bi-directional variable
displacement piston pump
0 - 25 gpm
0 - 1.6 liters/second
Maximum drive
pressure
Charge pressure
Eskridge brake
Mico brake
3800 psi
262 bar
360 psi
290 psi
3 micron
50 psi
345 kPa
29 seconds
25 seconds
Drive manifold
Primary boom up
27 seconds
35 seconds
Secondary boom up
25 seconds
25 seconds
73 seconds
15 seconds
Platform level up
25 seconds
15 seconds
Multiple function
stowed to full raised
60 seconds
Multiple function
full raised to stowed
60 seconds
2-2
24.8 bar
20 bar
22 bar
17.2 bar
3.0 gpm
11.4 liters/minute
4.5 gpm
17.0 liters/minute
7.0 gpm
26.5 liters/minute
Genie Z-45/22
Section 2 - Specifications
SPECIFICATIONS
Steer/oscillate manifold
2.1 cu in
34.4cc
Function pump
Type
Displacement
Function circuit return
line filter
Sequencing valve
pressure
1800 psi
123 bar
Accumulator
pre-charge pressure
1600 psi
110 bar
Auxillary pump
Type
Displacement
Auxillary pump
relief pressure
Function manifold
Function relief
valve pressure
2200 psi
152 bar
1200 psi
83 bar
1200 psi
83 bar
1200 psi
83 bar
Steer/oscillate
flow regulator
1.5 gpm
5.7 liters/minute
Genie Z-45/22
2-3
Section 2 - Specifications
Threads
No. 10
/4 inch
/16 inch
/8 inch
/16 inch
/2 inch
/16 inch
/8 inch
/4 inch
/8 inch
1 inch
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.
These bolt torque specifications are for general use only. Specification may vary depending on application
of bolt.
2-4
Genie Z-45/22
Section 2 - Specifications
Starter motor
140 cu in / 2.3 liters
Number of cylinders
Bore and stroke
4
3.780 x 3.126 inches
96 x 79.4mm
Horsepower
63 @4000 rpm
Firing order
1-3-4-2
High idle
2150 rpm
Low idle
1400 rpm
Governor
electronic
Compression pressure
Normal engine
cranking speed
110 rpm
150A
460A
70A
Maximum circuit
voltage drop (normal temp)
0.5V DC
0.50 inches
12.7mm
0.25 inches
6.35mm
55 - 75 inch-pounds
98 - 134gm-cm
Intake
Brush mounting
bolt torque
15 - 20 foot-pounds
2.1 - 2.7kg-m
Exhaust
Maximum commutator
run out
40 ounces
Valve clearances
Battery
Lubrication System
Oil pressure (operating
temp. @ 2150 rpm)
Oil capacity
(including filter)
40-60 psi
276-414 kPa
5 quarts
4.71 liters
Type
12V, Group 24
Ampere hour
75A
875A
0.005 inches
0.127mm
5W - 30
10W - 30
10W - 40 or 10W - 50
20W - 40 or 20W - 50
125 minutes
Fuel Pump
Static pressure
Minimum volume flow
Genie Z-45/22
2-5
Section 2 - Specifications
Ignition System
Ignition spark advance
Ignition coil
primary resistance
10 BTDC
1.13 - 1.25W (75F)
50-60
80-90
68-81
108-122
14-21
19-28
5-8
7-11
Ignition coil
secondary resistance
Motorcraft AWSF-52
Coolant capacity
11.5 quarts
10.9 liters
Alternator output
35A, 14.5V
3
/8 to 1/2 inch
9 to 12 mm
76-87
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
5-8
7-11
Torque
(ft-lbs)
Torque
(Nm)
28-40
38-54
6-9
8-12
28-40
38-54
14-21
19-28
5-10
7-14
50-71
68-96
Temperature sending
unit to block / M-14
8-18
11-24
6-9
8-12
23-28
31-38
7.5-15
10-20
Carburetor spacer to
manifold bolt / M-8
10-14
14-19
14-21
19-28
6-9
8-12
14-21
19-28
6-9
8-12
14-21
19-28
6-9
8-12
140-180
2-6
Genie Z-45/22
Section 2 - Specifications
125.02 cu in
2.049 liters
Number of cylinders
Bore and stroke
3
3.58 x 4.13 inches
91 x 105 mm
Horsepower
36 @ 2300 rpm
Firing order
1-2-3
Compression ratio
18.5:1
Compression pressure
4351 psi
300 bar
3626 psi
250 bar
Fuel requirement
Alternator output
0.7480 in
19 mm
0.5 in
12.7 mm
Battery
Type
High idle
2300 rpm
Quantity
Governor
centrifugal mechanical
1
1000A
Exhaust
0.020 in
0.5 mm
26 to 87 psi
1.8 to 6.0 bar
Oil capacity
(including filter)
8.5 quarts
8 liters
5W-30
10W-40
15W-40
200 minutes
3/8
to 1/2 inch
9 to 12 mm
torque
ft-lbs
torque
Nm
15 to 18
20 to 24
15 to 18
20 to 24
15 to 18
20 to 24
6 to 7
8 to 10
33 to 41
45 to 55
15 to 18
20 to 24
28 to 34
38 to 46
Lubrication system
12V, Group 31
Intake
90A
1300 rpm
Oil pressure
55A, 14V
Starter motor
Low idle
OMAP
Genie Z-45/22
2-7
Section 2 - Specifications
SPECIFICATIONS
27 to 32
30 to 36
15 to 18
7 to 8
torque
Nm
36 to 44
41 to 49
20 to 24
9 to 11
20 to 24
torque
ft-lbs
torque
Nm
37 to 44
50 to 60
5.5 to 7
7.5 to 9
5.5 to 7
7.5 to 9
14 to 16
19 to 22
14 to 16
19 to 22
15 to 18
15 to 18
20 to 24
15
20
15 to 18
20 to 24
95 to 105
30 to 37
40 to 50
15 to 18
20 to 24
Injection line
10 to 12
13.5 to 16.5
first step
tightening
torque
second step
tightening
angles
15 to 18
20 to 24
20 to 24
27 to 32
36 to 44
28 to 34
38 to 46
50 to 60
68 to 82
15 to 18
20 to 24
37 to 44
50 to 60
2-8
ft-lbs
Nm
1st
2nd
37
50
60
45
22
30
60
60
Flywheel bolts
22
30
60
30
22
59
118
30
80
160
120
NA
Camshaft/central bolt
22
30
150
NA
Crankshaft/central bolt
96
130
210
NA
Cylinder head
studs
Genie Z-45/22
step 1
step 2
step 3
New parts
required
The Schedule
Cold
engine
required
engine
required
Dealer
service
suggested
Table or Checklist
Daily
Quarterly
Annual
Two year
A+B
A+B+C
A+B+C+D
Maintenance Tables
Genie Z-45/22
3-1
Maintenance Tables
Table A
Tools are
required
A-1
A-2
A-3
A-4
A-5
A-6
A-7
A-8
A-9
A-10
A-11
A-12
A-13
New parts
required
Warm
engine
required
Cold
engine
required
Dealer
service
suggested
A-15
3-2
Genie Z-45/22
MAINTENANCE TABLES
Table B
Tools are
required
B-1
B-2
B-3
B-4
B-5
B-6
B-7
B-8
B-9
B-10
B-11
B-12
B-13
B-14
B-15
Genie Z-45/22
New parts
required
Warm
engine
required
Cold
engine
required
Dealer
service
suggested
3-3
MAINTENANCE TABLES
Table B, continued
Tools are
required
B-16
B-17
B-18
B-19
B-20
B-21
B-22
B-23
B-24
B-25
B-26
B-27
New parts
required
Warm
engine
required
Cold
engine
required
Dealer
service
suggested
3-4
Genie Z-45/22
MAINTENANCE TABLES
Table C
Tools are
required
C-1
C-2
C-3
C-4
C-5
C-6
C-7
C-8
C-9
C-10
C-11
C-12
C-13
C-14
C-15
Genie Z-45/22
New parts
required
Warm
engine
required
Cold
engine
required
Dealer
service
suggested
3-5
MAINTENANCE TABLES
Table D
Tools are
required
D-1
D-2
D-3
D-4
D-5
D-6
D-7
D-8
D-9
3-6
Genie Z-45/22
New parts
required
Warm
engine
required
Cold
engine
required
Dealer
service
suggested
Checklist A
Serial number
Refer to Table A
Tools areY
required
Warm
Cold
N New
R parts B-20 Engine
engine idle select
engine
required
required
required
B-21 Fuel
select-gasoline
A-1 Manuals
Date
Hour meter
Machine owner
Inspected by (print)
Inspector signature
Inspector company
Refer to Table C
Instructions
Make copies of this page to use for
each inspection.
Daily Inspection: A
Y N R
Dealer
service
suggested
Y N R
B-5 Battery
B-6 Hydraulic tank filter
Checklist D
Refer to Table D
Y N R
Genie Z-45/22
3-7
Tools are
required
New parts
required
Warm
engine
required
Cold
engine
required
Dealer
service
suggested
3-8
Genie Z-45/22
Symbols Legend
Genie Z-45/22
4-1
Table A Procedures
2 Inspect all decals for damage or illegibility.
Replace any illegible decal immediately.
A-1
Inspect the Manuals
Maintaining the Operator's 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 be sure that the storage container is
present and in good condition.
2 Check to make sure that the operator's,
responsibilities and safety manuals are present
and complete in the storage container in the
platform.
3 Examine the pages of each manual to be sure
that they are legible and in good condition.
4 Always return the manuals to the storage
container after use.
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
A-2
Inspect the
Decals and Placards
4-2
Genie Z-45/22
TABLE
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.
PROCEDURES
A-5
Check the Engine Coolant Level
- Gasoline/LPG Models
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.
5 quarts
4.7 liters
5W-30
10W-30
10W-40 or 10W-50
20W-40 or 20W-50
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.
8.5 quarts
8 liters
5W-30
10W-40
15W-40
Genie Z-45/22
4-3
TABLE
PROCEDURES
Gasoline/LPG models:
Dexron II equivalent
Tank capacity
25 gallons
95 liters
Hydraulic system
(including tank)
30 gallons
114 liters
A-7
Check the Hydraulic Oil Level
A-8
Check for Hydraulic Leaks
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:
hydraulic tankfilter, fittings, hoses and
turntable surface
4-4
Genie Z-45/22
TABLE
2WD Models
4WD Models
9-14.5LT
100 psi / 6.89 bar
14-17.5NHS
40 psi / 2.76 bar
14-17.5NHS
28 psi / 1.93 bar
A-10
Test the Platform and
Ground Controls
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.
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.
Part No. 32960
PROCEDURES
A-9
Industrial tire
A-11
Test Auxiliary Power Operation
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 Turn the key switch to ground control and pull
out the ground control Emergency Stop button
to the on position.
Genie Z-45/22
4-5
TABLE
PROCEDURES
A-13
Test the Limit Switches
5 Simultaneously hold
the auxiliary power
switch on while
activating the following
functions through a
partial cycle:
primary boom
up/ down
extend and retract
secondary boom up/down
turntable rotate right/left
steer left/right
A-12
Test the Tilt Level Sensor
missing fasteners
loose wiring
4-6
Genie Z-45/22
TABLE
PROCEDURES
Genie Z-45/22
4-7
TABLE
PROCEDURES
A-14
Replace the Engine Oil and Filter
- Gasoline/LPG Models
Ford 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.
a
b
4-8
Genie Z-45/22
TABLE
PROCEDURES
5 quarts
4.7 liters
b
a
b
c
5W-30
10W-30
10W-40 or 10W-50
20W-40 or 20W-50
Genie Z-45/22
4-9
TABLE
PROCEDURES
A-15
Replace the Engine Air Filter
Engine specifications require that
this procedure be performed every
100 hours. Perform this procedure
more often if dusty conditions
exist.
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.
Perform this procedure with the
engine off.
1 Remove the end cap from the air cleaner
canister.
2 Remove the mounting fastener from the air
filter, then remove the filter.
3 Clean the inside of the canister and the gasket
with a dry cloth.
4 Insert the new filter and replace the mounting
fastener.
5 Replace the end cap on the canister.
Air filters - Genie part numbers
Ford LSG-423 Engine
Deutz F3L 1011
27916
29553
4 - 10
Genie Z-45/22
Table B Procedures
B-1
Check the Engine Belt(s)
Maintaining the engine belt(s) 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.
B-2
Check the Radiator
- Gasoline/LPG Models
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
check allows the inspector to identify changes in
the condition of the radiator that might indicate
cooling system problems.
Do not inspect while the engine is
running. Remove the key to
secure from operation.
glazing
separation
breaks
3 Check the engine belt(s) for proper tension.
B-3
Check the Oil Cooler and Cooling
Fins - Deutz Diesel Models
Maintaining the oil cooler in good condition is
essential for good engine performance. Operating
a machine with a damaged oil cooler may result in
engine damage. Also, restricting air flow through
the oil cooler will affect the performance of the
cooling system.
Ford engine
3/8
Genie Z-45/22
4 - 11
TABLE B
PROCEDURES
Oil Cooler
B-5
Check the Battery
a
b
c
oil cooler
cylinder head cooling fins
blower fins
B-4
Check the Exhaust System
4 - 12
Genie Z-45/22
TABLE B
B-6
Check the Hydraulic Tank 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.
B-7
Inspect the Electrical Wiring
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.
Electrocution hazard. Contact with
hot or live circuits may result in
death or serious injury. Remove
all rings, watches and other
jewelry.
PROCEDURES
c
a
b
c
Genie Z-45/22
4 - 13
TABLE B
PROCEDURES
B-8
Inspect the Tires and Wheels
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.
An over-inflated tire can
explode and may cause death
or serious injury.
B-9
Confirm Proper
Brake Configuration
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.
1 Check the torque hub disconnect caps to be
sure they are in the engaged position.
Tire size
Tire ply rating
Tire pressure
2WD
Rough terrain
Industrial
14-17.5NHS
9-14.5 LT
Tread 8
Sidewall 6
40 psi
2.76 bar
28 psi
1.93 bar
100 psi
6.89 bar
125 ft-lbs
169.5 Nm
125 ft-lbs
169.5 Nm
Wheel diameter
17.5 inches
14.5 inches
Wheel width
10.5 inches
7 inches
9 @ 5/8-18
8 @ 5/8 -18
9 @ 5/8 -18
4WD
4 - 14
b
c
a
b
c
drive pump
lift pump
free-wheel valve
8 @ 5/8 -18
9 @ 5/8 -18
Genie Z-45/22
TABLE B
PROCEDURES
B-10
Check the Oil Level
in the Torque Hubs
B-11
Check and Adjust the Engine Idle
Mixture - Gasoline/LPG Models
B-12
Check and Adjust the
Engine 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.
Gasoline/LPG Models
17 fluid ounces
0.51 liters
Genie Z-45/22
4 - 15
TABLE B
PROCEDURES
a
b
b
Gasoline/LPG low idle adjustment
a
carburetor
b
adjustment screw
Gasoline/LPG models
Low idle - carburetor
900 rpm
1400 rpm
High idle
2150 rpm
4 - 16
Genie Z-45/22
TABLE B
f
e
c
a
b
c
d
e
f
B-13
Test the Key Switch
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.
solenoid boot
high idle adjustment nut
lock nut
yoke
low idle adjustment screw
lock nut
1300 rpm
High idle
2300 rpm
PROCEDURES
Genie Z-45/22
4 - 17
TABLE B
PROCEDURES
B-14
Test the Emergency Stop Buttons
B-15
Test the Ground Control Override
B-16
Test the Oscillate Lock-out
Perform this test on oscillating
axle equipped machines only.
4 - 18
Genie Z-45/22
TABLE B
PROCEDURES
B-17
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.
a
b
B-18
Test the Service Horn
3 inches
Genie Z-45/22
4 - 19
TABLE B
PROCEDURES
B-19
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.
B-20
Test the Engine Speed Select
4 - 20
Low idle
1400 rpm
High idle
2150 rpm
1300 rpm
High idle
2300 rpm
Genie Z-45/22
TABLE B
B-21
Test Fuel Select Operation Gasoline/LPG Models
PROCEDURES
B-22
Test the Turntable Rotation Stop
B-23
Test the Drive Enable System
Genie Z-45/22
4 - 21
TABLE B
PROCEDURES
B-24
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.
4 - 22
Genie Z-45/22
5.5 to 6 feet
1.67 to 1.82 m
TABLE B
PROCEDURES
B-25
B-26
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.
2WD
Genie Z-45/22
4 - 23
TABLE B PROCEDURES
B-28
Replace the Engine Oil and
Filter - Deutz Diesel Models
Engine specifications require
that this procedure be performed
every 500 hours. Perform this
procedure more often if dusty
conditions exist.
B-27
4 - 24
Genie Z-45/22
TABLE B PROCEDURES
8.5 quarts
8 liters
5W-30
10W-40
15W-40
Genie Z-45/22
4 - 25
Table C Procedures
C-1
Check the Primary Boom
Wear Pads
a
b
c
upper mid-pivot
4x4x31 inch block
counterweight
22
13
7
16
18
24
12
11
C-2
Check the Turntable Rotation
Bearing Bolts
15
8
14
4 - 26
23
17
5
21
10
19
Genie Z-45/22
TABLE C PROCEDURES
10
engage position
15
13
18
17
11
5
8
16
14
2
C-3
Check the Free-wheel Feature
Proper use of the free-wheel configuration is
essential to safe machine operation. The free-wheel
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.
b
c
Genie Z-45/22
a
b
c
drive pump
lift pump
free-wheel valve
4 - 27
TABLE C
PROCEDURES
C-4
Grease the Turntable Rotation
Bearing and Worm Drive Gear
a
b
b
a
b
grease fitting
grease overflow
upper mid-pivot
4x4x31 inch block
counterweight
Multipurpose grease
4 - 28
Genie Z-45/22
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 Tank Filter
Replacement of the hydraulic tank 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.
4 Fill the hub with oil from the top hole until the oil
level is even with the bottom of the side hole.
Apply pipe thread sealant to the plugs, and
then install the plugs.
Type
17 fluid ounces
0.5 liters
SAE 90 multipurpose
hypoid gear oil.
API classification GL5
Genie Z-45/22
4 - 29
TABLE C
PROCEDURES
C-7
Replace the
Drive Loop Hydraulic Filter
C-8
Replace the Diesel Fuel
Filter - Deutz Diesel Models
a
b
fuel filter
oil filter
4 - 30
Genie Z-45/22
TABLE C PROCEDURES
a
a
a
a
C-9
Replace the Gasoline Fuel Filter
Genie Z-45/22
4 - 31
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.
a
a
a
a
PCV valve
hose, PCV valve to carburetor
hose, PCV valve to crankcase
4 - 32
Genie Z-45/22
TABLE C PROCEDURES
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
Specifications
Spark Plugs (Motorcraft)
Gap
Torque specs
AWSF-42
0.032 - 0.036 inches
0.81 - 0.91mm
5 - 10 foot-pounds
6.8 - 13.6 Nm
a
b
c
d
Genie Z-45/22
4 - 33
TABLE C PROCEDURES
4 - 34
C-14
Check and Adjust the Ignition
Timing - 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.
C-15
Check the Engine Valve
Clearances - Deutz Diesel
Models
Complete information to perform this procedure
is available in the Deutz FL 1011 Workshop Manual
(Deutz Number 02611642). Genie part number
29789.
Genie Z-45/22
Table D Procedures
D-1
Test or Replace the Hydraulic Oil
Replacement or testing 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 often.
The machine uses Dexron II
equivalent hydraulic oil. Before
replacing the hydraulic oil, the oil
may be tested by an oil distributor
for specific levels of contamination
to verify that changing the oil is
necessary. If the hydraulic oil
is not replaced at the two year
inspection, quarterly testing
(B-27) thereafter should be
completed.
Perform this procedure with the
boom in the stowed position.
1 Close the two hydraulic shutoff valves located at
the hydraulic tank.
open
closed
Genie Z-45/22
4 - 35
TABLE D
PROCEDURES
D-2
Change or Recondition the
Engine Coolant
- Gasoline/LPG Models
All models:
25 gallons
95 liters
Hydraulic system
capacity (including tank)
30 gallons
114 liters
Hydraulic fluid
4 - 36
Dexron ll equivalent
Genie Z-45/22
TABLE D PROCEDURES
a
a
a
b
a
a
hose A
hard line B
Genie Z-45/22
11.5 quarts
10.9 liters
4 - 37
TABLE D
PROCEDURES
D-3
Change the Fuel Lines
4 - 38
Genie Z-45/22
TABLE D PROCEDURES
D-4
Check the Engine Valve
Clearance - Gasoline/LPG Models
D-5
Check the Engine Cylinder
Compression
- Gasoline/LPG Models
Complete information to perform this procedure is
available in the Ford LSG-423 2.3 Liter 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
Genie Z-45/22
4 - 39
TABLE D
PROCEDURES
D-6
Clean the PCV Hoses and
Fittings - Gasoline/LPG Models
a
b
4 - 40
Genie Z-45/22
TABLE D PROCEDURES
D-7
Check the Fuel Injection Pumps
and Injectors
- Deutz Diesel Models
Complete information to perform this procedure is
available in the Deutz FL 1011 Workshop Manual
(Deutz number: 0291 1942). Genie part number
29789.
D-8
Check the Toothed Belt
- Deutz Diesel Models
Complete information to perform this procedure is
available in the Deutz FL 1011 Operation Manual
(Deutz number: 0297 4706 EN). Genie part
number 29790.
D-9
Replace the Timing Belt
- Gasoline/LPG Models
Complete information to perform this procedure is
available in the Ford LSG-423 2.3 Liter Industrial
Engine Service Manual (Ford number: 194-216).
Genie part number 29586.
Genie Z-45/22
4 - 41
4 - 42
Genie Z-45/22
Genie Z-45/22
5-1
Identify
symptoms
Malfunction
discovered
Troubleshoot
problem
still exists
Return to
service
problem
solved
Inspect
and test
Perform
repair
5-2
Genie Z-45/22
Chart 1
Engine Will Not
Crank Over
Be sure the key switch
is in the appropriate
position.
Be sure the emergency
stop buttons are pulled
up into the on position.
Be sure the circuit
breaker(s) are not
tripped.
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5-3
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5-4
Genie Z-45/22
Chart 2
Engine Cranks
Over But Will
Not Start Gasoline/LPG
Models
Be sure to check the
engine oil level and fill
as needed.
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5-5
CHART 2
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5-6
Genie Z-45/22
CHART 2
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Genie Z-45/22
5-7
Chart 2A
Engine Cranks
Over But Will
Not Start Gasoline/LPG
Models
or
Engine Runs
While Cranking
Then Dies
Continuation of good
spark fault path.
Perform these tests in
gasoline mode only.
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VGMK
5-8
Genie Z-45/22
CHART 2A
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VGMK
Genie Z-45/22
5-9
CHART 2A
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UTKTMOTKIGXH[XKZUX
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]OXKIOXI[OZ)8ZU
GTZOJOKYKR\GR\K
<
8KVGOXUVKTOTHR[]NZ
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GTZOJOKYKR\GR\KZU
MGYUROTKYURKTUOJ
TU
8KIUTTKIZZNKZ]U
]OXKYZU\GI[[SY]OZIN
GTJINKIQLUXL[KRROTK
HRUIQGMK58XKVRGIK
GTZOJOKYKR\GR\K58YKK
,UXJYKX\OIKSGT[GRLUX
ZXU[HRKYNUUZOTML[KR
V[SVGTJUXIGXH[XKZUX
58)UTY[RZ-KTOK
/TJ[YZXOKY9KX\OIK
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<
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YURKTUOJGZMGYUROTK
ZGTQ
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KTMOTKLOXK%
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-UZUINGXZ(
VGMK
5 - 10
Genie Z-45/22
Chart 2B
Engine Runs
While Cranking
Then Dies
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SUJ[RK58IUTY[RZ
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RUIQU[ZSUJ[RKGTJ
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:(
8KVRGIKYZGXZRUIQU[Z
SUJ[RK58IUTY[RZ
-KTOK/TJ[YZXOKY
9KX\OIK*KVGXZSKTZ
Genie Z-45/22
5 - 11
Chart 3
Engine Cranks
Over But Will
Not Start Deutz Diesel
Models
Be sure to check the
engine oil level and fill
as needed.
.URJYZGXZY]OZINGTJ
INKIQHGZZKX_\URZGMK
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58INKIQGRZKXTGZUX58
INKIQLUXYNUXZIOXI[OZY
58INKIQHGZZKX_
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IUTZOT[OZ_ )NKIQOLUORIUURKX
GTJUXKTMOTKHRUIQ
LKKRYK^IKYYO\KR_NUZ
NUZ
TUZNUZ
Be sure to check
fuel level.
8KSU\K]NZXJ]OXK
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58UORIUURKXLOTYLUX
IRUMMOTM58INKIQ
KTMOTKLGTHKRZY58YKK
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LUXZXU[HRKYNUUZOTMGT
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8KVRGIKZKSVKXGZ[XK
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TUIUTZOT[OZ_
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IUTZOT[OZ_ 8KVGOXYNUXZOT]NZXJ
]OXKIOXI[OZLXUS:(ZU
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TUIUTZOT[OZ_
8KVGOXYNUXZOT]NZ]OXK
IOXI[OZLXUSYZGXZRUIQ
U[ZSUJ[RKZU:(58
IUTY[RZ-KTOK/TJ[YZXOKY
9KX\OIK*KVGXZSKTZ
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YZGXZKXYURKTUOJNURJ
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\URZGMKGZVUYOZO\K
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YURKTUOJ
<
)UTZOT[KJUTZNKTK^Z
VGMK
5 - 12
<
:[XTSGINOTKULLGTJ
OYURGZKZNKL[KRYURKTUOJ
)NKIQZNKXKYOYZGTIKUL
ZNKYURKTUOJ
UX
OTLOTOZK
UNSY
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YURKTUOJ
UNSY
9KK*K[Z`YKX\OIK
SGT[GRLUX
ZXU[HRKYNUUZOTML[KR
Y_YZKS
Genie Z-45/22
CHART 3
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INKIQ\URZGMKGZ]NZ
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UL)8
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YURKTUOJ
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)8
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ZKXSOTGR UL)8
<
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)8ZUZKXSOTGR UT
YZGXZRUIQU[ZSUJ[RK
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GTJUTYZGXZ
RUIQU[ZSUJ[RK
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YZGXZRUIQU[ZSUJ[RK
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RUIQU[ZSUJ[RK
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TUMUUJ
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]OXKZU)8
MUUJ
)UTZOT[KJUTZNKTK^Z
VGMK
Genie Z-45/22
5 - 13
CHART 3
)UTZOT[KJLXUSZNK
VXK\OU[YVGMK
)XGTQKTMOTKGTJINKIQ
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UTYZGXZRUIQU[ZSUJ[RK
<
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]OXKUTGRZKXTGZUX
<
8KVGOXUXXKVRGIK
GRZKXTGZUX58IUTZGIZ
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YKTJKXGTJINKIQ
IUTZOT[OZ_ZUMXU[TJUT
YOMTGRVUYZULYKTJKX
]NORKIXGTQOTMZNK
KTMOTK/YIUTZOT[OZ_
SGOTZGOTKJ%
_KY
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YKTJOTM[TOZ58XKLKXZU
*K[Z`YKX\OIKSGT[GR
LUXZXU[HRKYNUUZOTMRU]
UORVXKYY[XK
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RUIQU[ZSUJ[RK
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RUIQU[ZSUJ[RKGTJ
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SUJ[RK58IUTY[RZ
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XKJ]OXKIOXI[OZLXUS
:(
8KVRGIKYZGXZRUIQU[Z
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9KX\OIK*KVGXZSKTZ
5 - 14
Genie Z-45/22
Chart 4
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.
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ROTKLXUS26-ZGTQGTJ
HRKKJVXKYY[XKLXUS
ROTK
=OZNQK_Y]OZINUTGTJ
HUZNS[YNXUUS
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INKIQ\URZGMKGZ26YOJKHR[XKJ]OXKUL
L[KRYKRKIZY]OZIN
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Y]OZIN
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INKIQ\URZGMKGZ:(
<
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:(
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MUUJ
)UTZOT[KJUTZNKTK^Z
VGMK
Genie Z-45/22
5 - 15
CHART 4
)UTZOT[KJLXUSZNK
VXK\OU[YVGMK
<
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INKIQ\URZGMKGZ
ZKXSOTGR UT)8
8KVRGIK)8XKRG_
<
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]OXKUT26-YURKTUOJ
<
<
UX
OTLOTOZK
UNSY
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26-YURKTUOJ
8KVGOXUVKTOTHR[XKJ
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8KVRGIK26-YURKTUOJ
ZUUNSY
8KIUTTKIZ26-ZGTQ
GTJYZGXZKXZNKTYKK
3GOTZKTGTIKYKIZOUTLUX
26-GJP[YZSKTZY58
IUTY[RZ-KTOK/TJ[YZXOKY
9KX\OIK*KVGXZSKTZ
5 - 16
Genie Z-45/22
Chart 5
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.
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HUZNS[YNXUUS
Y]OZINKYV[RRKJU[Z
INKIQ\URZGMKGZ
MGYUROTKYOJKHR[]NZ
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Y]OZIN
<
8KVRGIKL[KRYKRKIZ
Y]OZIN
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:6ZU:(
<
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<
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HGJ
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)8
<
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HUZNS[YNXUUS
Y]OZINKYV[RRKJU[Z
INKIQ\URZGMKGZ:(
<
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<
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UT)8
<
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UTIGXH[XKZUX
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ZUGTZOJOKYKR\GR\K58
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<
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VGMK
Genie Z-45/22
5 - 17
CHART 5
)UTZOT[KJLXUSZNK
VXK\OU[YVGMK
.URJYZGXZY]OZINGTJ
INKIQ\URZGMKGZHR[]NZ
]OXKUTMGYUROTK
YURKTUOJGZL[KRZGTQ
<
<
UX
OTLOTOZK
UNSY
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MGYUROTKYURKTUOJ
8KVGOXUVKTOTHR[]NZ
]OXKIOXI[OZLXUS)8
ZUL[KRYURKTUOJ
8KVRGIKMGYUROTK
YURKTUOJ
ZUUNSY
HGJ
)NKIQMXU[TJ]OXKZU
MGYYURKTUOJ
MUUJ
UX
OTLOTOZK
UNSY
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GTZOJOKYKR\GR\K
8KVGOXMXU[TJ]OXK
8KVRGIKGTZOJOKYKR
\GR\K
ZUUNSY
8KIUTTKIZYZGXZKX
INKIQGTZOJOKYKRGTJ
L[KR\GR\KLUXJKLKIZY
58YKK,UXJYKX\OIK
SGT[GRLUXIGXH[XKZUX
ZXU[HRKYNUUZOTM
5 - 18
Genie Z-45/22
Chart 6
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.
9ZGXZKTMOTKGTJY]OZIN
XVSYKRKIZZUNOMNOJRK
XGHHOZY_SHURLUX
LURRU]OTMINKIQY)NKIQ
\URZGMKGZHRQXKJ]OXK
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Genie Z-45/22
5 - 19
CHART 6
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5 - 20
Genie Z-45/22
CHART 6
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KRKIZXUTOIMU\KXTUX
Genie Z-45/22
5 - 21
Chart 7
Engine Low Idle
Inoperative Gasoline/LPG
Models
If low idle operates
on LPG but not on
gasoline, see Ford
service manual for
carburetor
troubleshooting.
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.
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5 - 22
Genie Z-45/22
Chart 8
Engine
High Idle
Inoperative Deutz Diesel
Models
Be sure mechanical
linkage is not binding
or defective.
Be sure 2-speed
solenoid grounding
wires are free of
corrosion and have full
continuity to ground.
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Genie Z-45/22
5 - 23
CHART 8
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5 - 24
Genie Z-45/22
Chart 9
Engine
Low Idle
Inoperative Deutz Diesel
Models
Check if
mechanical linkage
from 2-speed
solenoid to fuel
injection system is
binding or defective.
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Genie Z-45/22
5 - 25
Chart 10
All Functions
Inoperative,
Engine Starts
and Runs
RU]
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5 - 26
Genie Z-45/22
Chart 11
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.
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8KVRGIKZNKV[SV
Genie Z-45/22
5 - 27
Chart 12
Ground
Controls
Inoperative,
Platform
Controls
Operate
Normally
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5 - 28
Genie Z-45/22
Chart 13
Platform
Controls
Inoperative,
Ground
Controls
Operate
Normally
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ZNKVRGZLUXSIUTZXURY%
Be sure all
cables are in good
condition with no
kinks or abrasions.
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Genie Z-45/22
5 - 29
Chart 14
Secondary
Boom Up
Function
Inoperative
Be sure all other
functions operate
normally.
If boom up function
operates normally from
the ground controls but
not from the platform
controls, troubleshoot
the platform controller.
See Repair section.
If boom up function
operates normally from
the platform controls but
not from the ground
controls, troubleshoot
the ground control
toggle switch. See
Repair section.
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5 - 30
Genie Z-45/22
CHART 14
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VXK\OU[YVGMK
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Genie Z-45/22
5 - 31
Chart 15
Secondary
Boom Down
Function
Inoperative
Be sure all other
functions operate
normally including
boom up function.
If boom down function
operates normally from
the ground controls but
not from the platform
controls, troubleshoot
the platform controller.
See Repair section.
If boom down function
operates normally from
the platform controls but
not from the ground
controls, troubleshoot
the ground control
toggle switch. See
Repair section.
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5 - 32
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Genie Z-45/22
CHART 15
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Genie Z-45/22
5 - 33
Chart 16
Primary
Boom Up
Function
Inoperative
Be sure all other
functions operate
normally.
If boom up function
operates normally
from the ground
controls but
not from the
platform controls,
troubleshoot the
platform controller.
See Repair section.
If boom up function
operates normally
from the platform
controls but
not from the ground
controls,
troubleshoot the
ground control
toggle switch. See
Repair section.
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5 - 34
Genie Z-45/22
CHART 16
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Genie Z-45/22
5 - 35
Chart 17
Primary
Boom Down
Function
Inoperative
Be sure all other
functions operate
normally including
boom up function.
If boom down
function operates
normally from the
ground controls but
not from the
platform controls,
troubleshoot the
platform controller.
See Repair section.
If boom down
function operates
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5 - 36
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Genie Z-45/22
CHART 17
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Genie Z-45/22
5 - 37
Chart 18
Primary Boom
Extend
Function
Inoperative
Be sure all other
functions operate
normally.
If boom extend function
operates normally from
the ground controls but
not from the platform
controls, troubleshoot
the platform controller.
See Repair section.
If boom extend function
operates normally from
the platform controls but
not from the ground
controls, troubleshoot
the ground control
toggle switch. See
Repair section.
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5 - 38
Genie Z-45/22
CHART 18
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Genie Z-45/22
5 - 39
Chart 19
Primary Boom
Retract
Function
Inoperative
Be sure all other
functions operate
normally including
boom 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.
5 - 40
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Genie Z-45/22
Chart 20
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.
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\GR\KIUORY
UX
OTLOTOZK
UNSY
8KVRGIKZNKJKLKIZO\K
\GR\KIUORY
ZUUNSY
8KVRGIKZNK\GR\K
L[TIZOUTOTUVKXGZO\K
)UTZOT[KJUTZNKTK^Z
VGMK
Genie Z-45/22
5 - 41
CHART 20
)UTZOT[KJLXUSZNK
VXK\OU[YVGMK
/TZKXINGTMKINKIQ\GR\K
OZKS1]OZNGROQK\GR\K
OZKS3
L[TIZOUT 8KVRGIKJKLKIZO\K
UVKXGZKY INKIQ\GR\K
L[TIZOUTOTUVKXGZO\K
/TYZGRRGZUVYO
VXKYY[XKMG[MKGZZNK
W[OIQJOYIUTTKIZ
IU[VROTMUTZNKL[TIZOUT
SGTOLURJGTJNURJZNK
L[TIZOUTY]OZIN
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)NKIQLUXSKINGTOIGR
XKYZXOIZOUTYQKKVOTM
Z[XTZGHRKLXUSXUZGZOTM
58INKIQXUZGZOUTSUZUX
58INKIQXUZGZOUTHXGQK
58INKIQXUZGZOUT
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RKYYZNGTVYO
8KVGOXXUZGZOUTSUZUX
58SGTOLURJNGY
OTZKXTGRJKLKIZIUTY[RZ
-KTOK/TJ[YZXOKY
9KX\OIK*KVGXZSKTZ
5 - 42
Genie Z-45/22
Chart 21
Turntable
Rotate Left
Function
Inoperative
.URJMXU[TJIUTZXUR
L[TIZOUTY]OZINGTJ
INKIQ\URZYGZ]NZHRQ
]OXKUTXUZGZKL[TIZOUT
JOXKIZOUTGR\GR\K
8KSU\KHUZN]OXKYLXUS
XUZGZKRKLZ\GR\KIUORGTJ
INKIQXKYOYZGTIKGIXUYY
ZNKIUORZKXSOTGRY
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8KVGOXUVKTOT]NZHRQ
]OXKIOXI[OZLXUS:(ZU
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<
UX
OTLOTOZK
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4UZK U\KXXOJOTMZNK
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G\GORGHRKOTZKXINGTMK
ZNK\GR\KOZKS6]OZNG
ROQK\GR\KOZKS9
L[TIZOUT
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JOXKIZOUTGR\GR\K
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IU[VROTMUTZNKL[TIZOUT
SGTOLURJGTJNURJZNK
L[TIZOUTY]OZIN
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RKYYZNGTVYO
8KSU\KZNKXUZGZKRKLZ
L[TIZOUTVXKYY[XKROTK
LXUSZNKSGTOLURJGTJ
IGVZNKVUXZ9
:NKT]OZNVXKYY[XK
MG[MKYZORRGZZGINKJ
UVKXGZKZNKL[TIZOUT
VYO
/TZKXINGTMKZNK
XUZGZKRKLZGTJXOMNZ
IU[TZKXHGRGTIK\GR\KY
OZKS3GTJOZKS4UT
Z[XTZGHRKXUZGZOUT
SUZUX
Ud]RcX^]
^_TaPcTb
8KVRGIKJKLKIZO\K
IU[TZKXHGRGTIK\GR\K
L[TIZOUTOTUVKXGZO\K
)NKIQLUXSKINGTOIGR
XKYZXOIZOUTYQKKVOTM
Z[XTZGHRKLXUSXUZGZOTM
RKLZ58XKVRGIK
JOXKIZOUTGR\GR\K58
XKVGOXXUZGZOUTSUZUX
8KVGOXXUZGZOUTSUZUX
RKYYZNGTVYO
8KVRGIKZNKJOXKIZOUTGR
\GR\K58ZNKSGTOLURJ
NGYOTZKXTGRJKLKIZY58
)UTY[RZ-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
Genie Z-45/22
5 - 43
Chart 22
Turntable
Rotate Right
Function
Inoperative
Be sure all other
functions operate
normally including
turntable rotate right
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.
.URJMXU[TJIUTZXUR
L[TIZOUTY]OZINGTJ
INKIQ\URZYGZ]NZ]OXK
UTXUZGZKL[TIZOUT
JOXKIZOUTGR\GR\K
<
8KVGOXUVKTOT]NZ]OXK
IOXI[OZLXUS:(ZU
JOXKIZOUTGR\GR\K
<
8KSU\KHUZN]OXKYLXUS
XUZGZKXOMNZ\GR\KIUOR
GTJINKIQXKYOYZGTIK
GIXUYYZNKIUOR
ZKXSOTGRY
UX
OTLOTOZK
UNSY
8KVRGIKZNK\GR\KIUOR
ZUUNSY
.URJZUMMRKY]OZINXOMNZ
GTJSGT[GRR_U\KXXOJK
XUZGZKXOMNZJOXKIZOUTGR
\GR\KV[YNOTH[ZZUTUT
KTJUL\GR\KYVUUR
4UZK U\KXXOJOTMZNK
\GR\K]ORRXKW[OXKZ]U
VKUVRK/LGNKRVKXOYTUZ
G\GORGHRKOTZKXINGTMK
ZNK\GR\KOZKS6]OZNG
ROQK\GR\KOZKS9
L[TIZOUT
UVKXGZKY 8KVRGIKZNKXUZGZK
JOXKIZOUTGR\GR\K
L[TIZOUTOTUVKXGZO\K
/TYZGRRGVXKYY[XKMG[MK
GZZNKW[OIQJOYIUTTKIZ
IU[VROTMUTZNKL[TIZOUT
SGTOLURJGTJNURJZNK
L[TIZOUTY]OZIN
VYO
/TZKXINGTMKZNK
XUZGZKXOMNZGTJRKLZ
IU[TZKXHGRGTIK\GR\KY
OZKS3GTJOZKS4UT
Z[XTZGHRKXUZGZOUT
SUZUX
L[TIZOUT 8KVRGIKJKLKIZO\K
UVKXGZKY IU[TZKXHGRGTIK\GR\K
L[TIZOUTOTUVKXGZO\K
RKYYZNGTVYO
8KSU\KZNKXUZGZKXOMNZ
L[TIZOUTVXKYY[XKROTK
LXUSZNKSGTOLURJGTJ
IGVZNKVUXZ9
:NKT]OZNVXKYY[XK
MG[MKYZORRGZZGINKJ
UVKXGZKZNKL[TIZOUT
VYO
)NKIQLUXSKINGTOIGR
XKYZXOIZOUTYQKKVOTM
Z[XTZGHRKLXUSXUZGZOTM
XOMNZ58XKVRGIK
JOXKIZOUTGR\GR\K58
XKVGOXXUZGZOUTSUZUX
8KVGOXXUZGZOUTSUZUX
RKYYZNGTVYO
8KVRGIKZNKJOXKIZOUTGR
\GR\K58ZNKSGTOLURJ
NGYOTZKXTGRJKLKIZY
5 - 44
58
)UTY[RZ-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
Genie Z-45/22
Chart 23
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.
.URJMXU[TJIUTZXUR
L[TIZOUTY]OZINGTJ
INKIQ\URZGMKGZUXMXKJ
]OXKUTVRGZLUXSRK\KR
LRU]IUTZXUR\GR\K
<
8KSU\KHUZN]OXKYLXUS
\GR\KIUORGTJINKIQ
XKYOYZGTIKGIXUYYIUOR
ZKXSOTGRY
<
UX
OTLOTOZK
UNSY
8KVGOXUXMXKJ]OXK
IOXI[OZLXUS:(ZULRU]
IUTZXUR\GR\K
8KVRGIKZNKIUOR
ZUUNSY
8KSU\KHUZNN_JXG[ROI
NUYKYLXUSZNKSGTOLURJ
VUXZY62626R[M
ZNKNUYKYGTJIGVZNK
SGTOLURJLOZZOTMY
5VKXGZKHUUS[V
L[TIZOUTGTJINKIQOL
VRGZLUXSRK\KRY
_KY
8KVRGIKZNK
IU[TZKXHGRGTIK\GR\KY
OZKSY()UX\GR\K
HRUIQ'
VYO
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XKYZXOIZOUTY58XKVRGIK
ZNKYRG\KI_ROTJKX
IU[TZKXHGRGTIK\GR\KY
TU
6R[SHGVXKYY[XKMG[MK
OTZUZNKSGYZKXI_ROTJKX
HGXXKRKTJN_JXG[ROI
NUYK[YOTMGZKKLOZZOTM
5VKXGZKHUUS[V
L[TIZOUTGTJXKGJ
ZNKVXKYY[XK
RKYYZNGTVYO
*KGJNKGJZNKVXKYY[XK
MG[MKOTZUZNKHGXXKR
KTJN_JXG[ROINUYKLXUS
ZNKSGYZKXI_ROTJKXGTJ
XGOYKZNKHUUSUTKOTIN
GZGZOSK)UTZOT[GRR_
SUTOZUXZNKVXKYY[XK
MG[MKJ[XOTMHUUS[V
*UTUZGRRU]ZNK
VXKYY[XKZUK^IKKJ
VYO
RKYY
ZNGT
VYO 8KVGOXUXXKVRGIKZNK
SGYZKXI_ROTJKX
VYOUXSUXK
8KVGOXUXXKVRGIKZNK
YRG\KI_ROTJKX
Genie Z-45/22
5 - 45
Chart 24
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.
.URJMXU[TJIUTZXUR
L[TIZOUTY]OZINGTJ
INKIQ\URZGMKGZUXM
]OXKUTVRGZLUXSRK\KR[V
L[TIZOUTJOXKIZOUTGR
\GR\K
<
8KVGOXUVKTOTUXM]OXK
IOXI[OZLXUS:(ZU
JOXKIZOUTGR\GR\K
<
8KSU\KHUZN]OXKYLXUS
\GR\KIUORGTJINKIQ
XKYOYZGTIKGIXUYYZNK
IUORZKXSOTGRY
UX
OTLOTOZK
UNSY
8KVRGIKZNKIUOR
ZUUNSY
.URJZUMMRKY]OZINGTJ
SGT[GRR_U\KXXOJKZNK
RK\KR[VJOXKIZOUTGR
\GR\KV[YNOTH[ZZUT
UTKTJUL\GR\KYVUUR
4UZK U\KXXOJOTMZNK
\GR\K]ORRXKW[OXKZ]U
VKUVRK/LGNKRVKXOYTUZ
G\GORGHRKOTZKXINGTMK
ZNK\GR\KOZKS5]OZN
GROQK\GR\KOZKS4
L[TIZOUT
UVKXGZKY 8KVRGIKZNKVRGZLUXS
RK\KROTMJOXKIZOUTGR
\GR\K
L[TIZOUTOTUVKXGZO\K
/TZKXINGTMKINKIQ\GR\K
OZKS2]OZNROQK\GR\K
OZKS1
L[TIZOUT
UVKXGZKY 8KVRGIKJKLKIZO\K
INKIQ\GR\K
L[TIZOUTOTUVKXGZO\K
/TYZGRRGVXKYY[XKMG[MK
GZZNKW[OIQJOYIUTTKIZ
IU[VROTMUTZNKL[TIZOUT
SGTOLURJGTJNURJZNK
L[TIZOUTY]OZIN
VYOUX
SUXK
/TZKXINGTMKZNK
RK\KR[VGTJJU]T
IU[TZKXHGRGTIK\GR\KY
OZKSY()
VYOUX
SUXK
L[TIZOUTUVKXGZKY
RKYYZNGTVYO
8KVRGIKJKLKIZO\K
IU[TZKXHGRGTIK\GR\K
*OYIUTTKIZOTMN_JXG[ROI
ROTKYUXGJP[YZOTMZNK
I_ROTJKXIU[TZKXHGRGTIK
\GR\KYOTZNOYYOZ[GZOUT
IGTHK\KX_JGTMKXU[Y
6RKGYKIUTY[RZ-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
8KVRGIKZNKJOXKIZOUTGR
\GR\K58ZNKSGTOLURJ
NGYOTZKXTGRJKLKIZY58
UTKULZNKVXK\OU[Y
ZKYZY]GYVUYYOHR_
U\KXRUUQKJUX
JOGMTUYKJOTIUXXKIZR_
8KINKIQGTJUXIUTY[RZ
-KTOK/TJ[YZXOKY
9KX\OIK*KVGXZSKTZ
5 - 46
Genie Z-45/22
Chart 25
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.
.URJMXU[TJIUTZXUR
L[TIZOUTY]OZINGTJ
INKIQ\URZGMKGZUXMHRQ
]OXKUTVRGZLUXSRK\KR
JU]TL[TIZOUT
JOXKIZOUTGR\GR\K
<
8KVGOXUVKTOTUXMHRQ
]OXKIOXI[OZLXUS:(
ZUJOXKIZOUTGR\GR\K
<
8KSU\KHUZN]OXKYLXUS
\GR\KIUORGTJINKIQ
XKYOYZGTIKGIXUYYZNK
IUORZKXSOTGRY
UX
OTLOTOZK
UNSY
8KVRGIKZNKIUOR
ZUUNSY
.URJZUMMRKY]OZINGTJ
SGT[GRR_U\KXXOJKZNK
RK\KRJU]TJOXKIZOUTGR
\GR\KV[YNOTH[ZZUT
UTKTJUL\GR\KYVUUR
4UZK U\KXXOJOTMZNK
\GR\K]ORRXKW[OXKZ]U
VKUVRK/LGNKRVKXOYTUZ
G\GORGHRKOTZKXINGTMK
ZNK\GR\KOZKS5]OZN
GROQK\GR\KOZKS4
L[TIZOUT
UVKXGZKY 8KVRGIKZNKVRGZLUXS
RK\KROTMJOXKIZOUTGR
\GR\K
L[TIZOUTOTUVKXGZO\K
/TZKXINGTMKINKIQ\GR\K
OZKS2]OZNROQK\GR\K
OZKS1
L[TIZOUT
UVKXGZKY 8KVRGIKJKLKIZO\K
INKIQ\GR\K
L[TIZOUTOTUVKXGZO\K
/TYZGRRGVXKYY[XKMG[MK
GZZNKW[OIQJOYIUTTKIZ
IU[VROTMUTZNKL[TIZOUT
SGTOLURJGTJNURJZNK
L[TIZOUTY]OZIN
VYOUX
SUXK
/TZKXINGTMKZNKRK\KR[V
GTJJU]T
IU[TZKXHGRGTIK\GR\KY
OZKSY()
VYOUX
SUXK
L[TIZOUTUVKXGZKY
RKYYZNGTVYO
8KVRGIKJKLKIZO\K
IU[TZKXHGRGTIK\GR\K
*OYIUTTKIZOTMN_JXG[ROI
ROTKYUXGJP[YZOTMZNK
I_ROTJKXIU[TZKXHGRGTIK
\GR\KYOTZNOYYOZ[GZOUT
IGTHK\KX_JGTMKXU[Y
6RKGYKIUTY[RZ-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
8KVRGIKZNKJOXKIZOUTGR
\GR\K58ZNKSGTOLURJ
NGYOTZKXTGRJKLKIZY58
UTKULZNKVXK\OU[Y
ZKYZY]GYVUYYOHR_
U\KXRUUQKJUX
JOGMTUYKJOTIUXXKIZR_
8KINKIQGTJUXIUTY[RZ
-KTOK/TJ[YZXOKY
9KX\OIK*KVGXZSKTZ
Genie Z-45/22
5 - 47
Chart 26
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 platform
controls,
troubleshoot the
platform control
toogle 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.
.URJMXU[TJIUTZXUR
L[TIZOUTY]OZINGTJ
INKIQ\URZGMKGZMXTHRQ
]OXKUTVRGZLUXSXUZGZK
RKLZL[TIZOUTJOXKIZOTGR
\GR\K
8KVGOXUVKTOTMXTHRQ
]OXKIOXI[OZLXUS:(ZU
JOXKIZOUTGR\GR\K
<
<
8KSU\KHUZN]OXKYLXUS
\GR\KIUORGTJINKIQ
XKOYOZGTIKGIXUYYIUOR
ZKXSOTGRY
UXOTLOTOZKUNSY
8KVRGIKZNKIUOR
ZUUNSY
.URJZUMMRKY]OZINRKLZ
GTJSGT[GRR_U\KXXOJK
XUZGZKRKLZJOXKIZOUTGR
\GR\KV[YNOTH[ZZUTUT
KTJUL\GR\KYVUUR
4UZK U\KXXOJOTM\GR\K
]ORRXKW[OXKZ]UVKUVRK
/LGNKRVKXOYTUZ
G\GORGHRKOTZKXINGTMK
ZNK\GR\KOZKS4]OZNG
ROQK\GR\KOZKS5
Ud]RcX^]^_TaPcTb
8KVRGIKVRGZLUXSXUZGZK
JOXKIZOUTGR\GR\K
L[TIZOUTOTUVKXGZO\K
/TYZGRRGVXKYY[XKMG[MK
GZW[OIQJOYIUTTKIZ
IU[VROTMUTXUZGZK
L[TIZOUTSGTOLURJGTJ
NURJL[TIZOUTY]OZIN
VYOUXSUXK
VYO
/TZKXINGTMKINKIQ\GR\K
OZKS.]OZNROQK\GR\K
OZKS2
Ud]RcX^]^_TaPcTb
)NKIQLUXSKINGTOIGR
XKYZXOIZOUTY58
N_JXG[ROIXUZGZUXUX
L[TIZOUTSGTOLURJNGY
OTZKXTGRJKLKIZ)UTY[RZ
-KTOK/TJ[YZXOKY
9KX\OIK*KVGXZSKTZ
8KVRGIKJKLKIZO\K
INKIQ\GR\K
L[TIZOUTOTUVKXGZO\K
8KVRGIKJOXKIZOUTGR
\GR\K58SGTOLURJNGY
OTZKXTGRJKLKIZY58
IUTY[RZ-KTOK/TJ[YZXOKY
9KX\OIK*KVGXZSKTZ
5 - 48
Genie Z-45/22
Chart 27
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 platform
controls,
troubleshoot the
platform control
toogle 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.
.URJMXU[TJIUTZXUR
L[TIZOUTY]OZINGTJ
INKIQ\URZGMKGZMXT
]OXKUTVRGZLUXSXUZGZK
XOMNZL[TIZOUTJOXKIZOUTGR
\GR\K
8KVGOXUVKTOTMXT]OXK
IOXI[OZLXUS:(ZU
JOXKIZOUTGR\GR\K
<
<
8KSU\KHUZN]OXKYLXUS
\GR\KIUORGTJINKIQ
XKOYOZGTIKGIXUYYIUOR
ZKXSOTGRY
UXOTLOTOZKUNSY
8KVRGIKZNKIUOR
ZUUNSY
.URJZUMMRKY]OZINXOMNZ
GTJSGT[GRR_U\KXXOJK
XUZGZKRKLZJOXKIZOUTGR
\GR\KV[YNOTH[ZZUTUT
KTJUL\GR\KYVUUR
4UZK U\KXXOJOTM\GR\K
]ORRXKW[OXKZ]UVKUVRK
/LGNKRVKXOYTUZ
G\GORGHRKOTZKXINGTMK
ZNK\GR\KOZKS4]OZNG
ROQK\GR\KOZKS5
Ud]RcX^]^_TaPcTb
8KVRGIKVRGZLUXSXUZGZK
JOXKIZOUTGR\GR\K
L[TIZOUTOTUVKXGZO\K
/TYZGRRGVXKYY[XKMG[MK
GZW[OIQJOYIUTTKIZ
IU[VROTMUTXUZGZK
L[TIZOUTSGTOLURJGTJ
NURJL[TIZOUTY]OZIN
VYOUXSUXK
VYO
/TZKXINGTMKINKIQ\GR\K
OZKS/]OZNROQK\GR\K
OZKS2
Ud]RcX^]^_TaPcTb
)NKIQLUXSKINGTOIGR
XKYZXOIZOUTY58
N_JXG[ROIXUZGZUXUX
L[TIZOUTSGTOLURJNGY
OTZKXTGRJKLKIZ)UTY[RZ
-KTOK/TJ[YZXOKY
9KX\OIK*KVGXZSKTZ
8KVRGIKJKLKIZO\K
INKIQ\GR\K
L[TIZOUTOTUVKXGZO\K
8KVRGIKJOXKIZOUTGR
\GR\K58SGTOLURJNGY
OTZKXTGRJKLKIZY58
IUTY[RZ-KTOK/TJ[YZXOKY
9KX\OIK*KVGXZSKTZ
Genie Z-45/22
5 - 49
Chart 28
Oscillate
Lock-out
Function
Inoperative
8GOYKZNKVXOSGX_HUUS
[TZOROZOYGHU\KZNKJXO\K
ROSOZY]OZINGTJ
SKGY[XKZNKUYIORRGZK
RUIQU[Z]KJMKY9KK
3GOTZKTGTIK
6XUIKJ[XKY(
]KJMKY
K^ZKTJ )NKIQ\URZGMKGZHRQ
OTINKY
8]OXKUT)8GTJ
)8
<
]KJMKYJUTUZ
K^ZKTJOTINKY
)NKIQ\URZGMKGZHRQ
8UT)8
<
5VKTOTXKJ ]OXK
<Y[VVR_ZUUYIORRGZK
ROSOZY]OZINKY58UTKUX
HUZNUYIORRGZKROSOZ
Y]OZINKYOYJKLKIZO\K
)NKIQ)8GTJ)8
MXKKTMXU[TJOTM]OXK
58XKVRGIK)8UX
)8XKRG_YUX
YUIQKZY
<
*XO\KROSOZY]OZIN
YNUXZKJXKVGOXUX
XKVRGIK
<
8KVRGIK)8XKRG_UX
XKRG_YUIQKZ58XKVGOX
YNUXZOT]NZ 8]OXK
IOXI[OZLXUS)8ZU
UYIORRGZK\GR\K
<
)NKIQ\URZGMKGZ]NZ
8UTUYIORRGZK\GR\K
<
8KSU\KSGINOTKLXUS
YKX\OIKGTJVRKGYK
IUTY[RZ-KTOK/TJ[YZXOKY
9KX\OIK*KVGXZSKTZ
5 - 50
Genie Z-45/22
Chart 29
Steer Left
Function
Inoperative
Be sure all other
functions operate
normally.
9ZGXZZNKKTMOTKLXUS
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JU]TLUUZY]OZINNURJ
ZNKYZKKXY]OZINRKLZGTJ
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IUTZXURRKXHR[]OXK
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8KSU\KHUZN]OXKYLXUS
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UX
OTLOTOZK
UNSY
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\GR\KIUOR
ZUUNSY
8KVRGIKYZKKX\GR\K58
IUTY[RZ-KTOK/TJ[YZXOKY
9KX\OIK*KVGXZSKTZ
Genie Z-45/22
5 - 51
Chart 30
Steer Right
Function
Inoperative
Be sure all other
functions operate
normally.
9ZGXZZNKKTMOTKLXUS
ZNKVRGZLUXSVXKYY
JU]TLUUZY]OZINNURJ
ZNKYZKKXY]OZINXOMNZ
GTJINKIQ\URZGMKGZ
ZKXSOTGRUTZNKJXO\K
IUTZXURRKXHR[HRQ]OXK
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8KVGOXUXXKVRGIKZNK
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Y]OZINZU:6ZU:(
<
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<
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UX
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UNSY
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\GR\KIUOR
ZUUNSY
8KVRGIKYZKKX\GR\K58
IUTY[RZ-KTOK/TJ[YZXOKY
9KX\OIK*KVGXZSKTZ
5 - 52
Genie Z-45/22
Chart 31
All Drive
Functions
Inoperative,
All Other
Functions
Operate
Normally
Be sure the
hydraulic suction
line valve is in the
open position.
Be sure machine
not in the free
wheel configuration.
Be sure the drive
speed select switch
is set to machine on
level surface
position (maximum
drive speed).
9ZGXZKTMOTKLXUS
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RK\KXOTKGINJOXKIZOUT
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JXO\KY
:(GTJZKYZJXO\K
]OZNU[ZNURJOTMJXO\K
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8KVGOXUVKTOT
]NZ]OXKIOXI[OZLXUS
:6ZU:(
SGINOTKJXO\KY
8KVRGIKJXO\KKTGHRK
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UVKTOT]OXKIOXI[OZY
LXUSZKXSOTGR:(ZU
ROSOZY]OZINGTJLXUS
ROSOZY]OZINZU:(
TUJXO\K
*OYIUTTKIZJXO\KV[SV
KRKIZXUTOIJOYVRGIKSKTZ
IUTZXURRKX+*)]OXKY
)NKIQXKYOYZGTIK
GIXUYYHUZN]OXKYUT
+*)YOJKULW[OIQ
JOYIUTTKIZ
UX
OTLOTOZK
UNSY
8KVRGIK+*)
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GTJINKIQ\URZGMKGZ
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HUGXJZKXSOTGR
RKYYZNGT<
<UXSUXK
)UXXKIZOTY[LLOIOKTZ
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GRZKXTGZUXUXHGZZKX_
58XKVGOXUVKTOT]NZ
]OXKIOXI[OZY[VVR_OTM
<ZUZKXSOTGR
)UTZOT[KJUTZNKTK^Z
VGMK
Genie Z-45/22
5 - 53
CHART 31
)UTZOT[KJLXUSZNK
VXK\OU[YVGMK
9]OZINXVSYKRKIZ
Y]OZINZUXGHHOZ]OZNLUUZ
Y]OZINVXKYYJU]TLUUZ
Y]OZINGTJINKIQ
\URZGMKGZZKXSOTGRUT
NUXYKVU]KXROSOZKX
<
)NKIQ\URZGMKGZ:(
ZU<
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]OXKIOXI[OZLXUS:(ZU
NUXYKVU]KXROSOZKX
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]OXKIOXI[OZLXUS
GRZKXTGZUXZU:(
<
)NKIQ\URZGMKGZ
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GRZKXTGZUX
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8KVGOXUXXKVRGIK
GRZKXTGZUX
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GTJINKIQ\URZGMKGZ
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8KVRGIKNUXYKVU]KX
ROSOZKXHUGXJ
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IUTZXURRKX
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ROSOZKXHUGXJZUJXO\K
IUTZXURZKXSOTGR
ZU<
)UTZOT[KJUTZNKTK^Z
VGMK
5 - 54
Genie Z-45/22
CHART 31
)UTZOT[KJLXUSZNK
VXK\OU[YVGMK
*OYIUTTKIZJXO\KV[SV
+*)]OXKYVXKYYJU]T
LUUZY]OZINNURJJXO\K
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VUYOZOUTGTJINKIQ
\URZGMKGIXUYY
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UTJXO\KIUTZXURRKX
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IUTZXURRKX
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L[RRLUX]GXJVUYOZOUT
GTJINKIQ\URZGMK
GIXUYYZKXSOTGRY
:6GTJ:6
<
8KVGOXUVKTOTKOZNKX
]NZUX]NZHRQ]OXK
IOXI[OZLXUSJXO\K
IUTZXURRKXZU:6GTJ
:6XKYVKIZO\KR_
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6XKYYJU]TLUUZY]OZIN
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GTJINKIQ\URZGMK
GIXUYYZKXSOTGRY
:(GTJ:(
<
8KVGOXUVKTOTKOZNKX
]NZUX]NZHRQ]OXK
IOXI[OZLXUS:(GTJ
:(XKYVKIZO\KR_
ZU<
6XKYYJU]TLUUZY]OZIN
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INKIQ\URZGMKGIXUYY
ZNKZ]U]OXKYGZ+*)
W[OIQJOYIUTTKIZ
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8KVGOXUVKTOT]NZHRQ
]OXKIOXI[OZLXUS:(ZU
+*)W[OIQJOYIUTTKIZ
58XKVGOXUVKTOT]NZ
]OXKIOXI[OZLXUS:(ZU
+*)W[OIQJOYIUTTKIZ
ZU<
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+*)58IUTY[RZ-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
Genie Z-45/22
5 - 55
Chart 32
Drive
Forward Or
Reverse
Function
Inoperative
Be sure all other
functions operate
normally including
drive in opposite
direction of
malfunction.
*OYIUTTKIZZNK+*)
]OXKIUTTKIZUXLXUSZNK
JXO\KV[SVYZGXZ
KTMOTKSU\KZNKJXO\K
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VUYOZOUTGTJTUZKZNK
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:(GTJ:(
8K\KXYKZNK\URZSKZKX
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8KVGOXUXXKVRGIKZNK
JXO\KIUTZXURRKX
\URZGMKXKGJOTMYZNKYGSK
'JP[YZZNKJXO\KV[SV
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9[TJYZXGTJ9KXOKY
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TUOSVXU\KSKTZ
*KLKIZO\K9[TJYZXGTJ
JXO\KV[SVIUTZGIZ
9[TJYZXGTJG[ZNUXO`KJ
XKVGOXLGIOROZ_
Y_SVZUSYOSVXU\K
)NKIQGRRJXO\KYVKKJY
GTJSUTOZUXLUX
XKI[XXOTMY_SVZUSY
6UYYOHRKIUTZGSOTGZOUT
OTN_JXG[ROIY_YZKS
5 - 56
Genie Z-45/22
Chart 33
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.
9ZGXZKTMOTKLXUS
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UTLUUZY]OZIN(KY[XK
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8KVGOXUVKTOTUXMHRQ
]OXKIOXI[OZLXUS
GRZKXTGZUXZU:(
<
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-KTOK/TJ[YZXOKY
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]OXKUTIKTZKXZKXSOTGR
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IUTZXURRKX
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IOXI[OZLXUSNUXYKVU]KX
8KVGOXUXXKVRGIK
ROSOZKXHUGXJZKXSOTGR
GRZKXTGZUX58IUTY[RZ
ZUIKTZKXZKXSOTGR
-KTOK/TJ[YZXOKY
UTJXO\KYVKKJYKRKIZ
9KX\OIK*KVGXZSKTZ
Y]OZIN
8KVGOXUVKTOTXKJ]OXK
IOXI[OZLXUSJXO\KYVKKJ
YKRKIZY]OZIN58
XKVRGIKJXO\KYVKKJ
YKRKIZY]OZIN
)UTZOT[KJUTZNKTK^Z
VGMK
Genie Z-45/22
5 - 57
CHART 33
)UTZOT[KJLXUSZNK
VXK\OU[YVGMK
6XKYYJU]TZNKLUUZ
Y]OZINGTJINKIQ
\URZGMKGZZKXSOTGR
:(
<
6XKYYJU]TLUUZY]OZIN
GTJINKIQ\URZGMKGZ
:6
<
8KVGOXUVKTOTXKJ]NZ
]OXKIOXI[OZLXUS:6ZU
:(
<
8KVGOXUVKTOTXKJ]NZ
]OXKIOXI[OZLXUSZUMMRK
Y]OZINZU:6
<
6XKYYJU]TLUUZY]OZIN
GTJINKIQ\URZGMKGZ
XKJ]NZ]OXKUTJXO\K
SUJKYKRKIZY]OZIN
<
6XKYYJU]TLUUZY]OZIN
GTJINKIQ\URZGMKGZ
]NZ]OXKY[VVR_OTM<
ZUJXO\KSUJKYKRKIZ
Y]OZIN
<
<
8KVRGIKZUMMRKY]OZIN
<
8KVGOXUVKTOT]NZ]OXK
IOXI[OZY[VVR_OTM<ZU
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6XKYYJU]TLUUZY]OZIN
GTJINKIQ\URZGMKGZ
XKJ]NZ ]OXKUTZNK
SUZUXYZXUQKYURKTUOJ
\GR\KOZKS4
<
8KVGOXUVKTOTXKJ]NZ
]OXKIOXI[OZLXUS
:(ZUYZXUQKYURKTUOJ
\GR\K
<
6XKYYJU]TLUUZY]OZIN
GTJINKIQ\URZGMKGZ
XKJ]NZ ]OXKUT
ZKXSOTGRULZOSKJKRG_
XKRG_:8
<
8KVGOXUVKTOTXKJ]NZ
]OXKIOXI[OZLXUS
:(ZUZOSKJKRG_
XKRG_
<
)NKIQ\URZGMKGZ]NZ
]OXKUTZKXSOTGR
ULZOSKJKRG_XKRG_
<
6XKYYJU]TLUUZY]OZIN
GTJINKIQ\URZGMKGZHRQ
:8]OXKUTZKXSOTGR
ULZOSKJKRG_XKRG_
<
8KVGOXUVKTOT]NZ
]OXKIOXI[OZ
HGJ
8KVGOXUVKTOTMXU[TJ
]OXK
<
<
)UTZOT[KJUTZNKTK^Z
VGMK
)NKIQMXU[TJ]OXKZU
ZOSKJKRG_XKRG_
MUUJ
8KVRGIKZOSKJKRG_
XKRG_
5 - 58
Genie Z-45/22
CHART 33
)UTZOT[KJLXUSZNK
VXK\OU[YVGMK
6XKYYJU]TLUUZY]OZIN
GTJINKIQ\URZGMKGZHRQ
:8]OXKUTZXGIZOUT
H_VGYYYURKTUOJ\GR\K
OZKS7
<
8KVGOXUVKTOTHRQ :8
]OXKIOXI[OZLXUSZOSK
JKRG_XKRG_ZUZXGIZOUT
H_VGYY\GR\K
<
/TZKXINGTMKZXGIZOUT
H_VGYY\GR\KOZKS7
]OZNTK]YURKTUOJ\GR\K
GTJINKIQNOMNJXO\K
TUNOMNJXO\K
8KVRGIKZXGIZOUTH_VGYY
GTJOTZKXINGTMKTK]
\GR\K]OZNSUZUXYZXUQK
\GR\KOZKS7GTJ
INKIQNOMNJXO\K
TUNOMN
JXO\K
8KVRGIKZXGIZOUTH_VGYY
YN[ZZRK\GR\KOZKS7
GTJINKIQNOMNJXO\K
Genie Z-45/22
TUNOMN
JXO\K
)UTY[RZ-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
5 - 59
Chart 34
Low Range
Drive
Function
Inoperative
Be sure all other
functions operate
normally including
drive high range
(two wheel symbol).
:[XTQK_Y]OZINZU
VRGZLUXSIUTZXURYV[RR
HUZNKSKXMKTI_YZUV
H[ZZUTYUTY]OZINJXO\K
SUJKZURU]XGTMK
SGINOTKUTOTIROTK
Y_SHURVXKYYJU]T
LUUZY]OZINGTJINKIQ
\URZGMKGZXKJ]NZ]OXK
UTJXO\KSUJKY]OZIN
<
8KVRGIKJXO\KSUJK
ZUMMRKY]OZIN
<
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]OXKIOXI[OZLXUSJXO\K
SUJKY]OZINZNXU[MN
:6ZU:(
<
8KVRGIK:8ZOSKJKRG_
XKRG_
<
6XKYYJU]TLUUZY]OZIN
GTJINKIQ\URZGMKGZ
:(
<
6XKYYJU]TLUUZY]OZIN
GTJINKIQ\URZGMKGZHRQ
:8UTZXGIZOUTH_VGYY
\GR\KOZKS7
<
/TZKXINGTMKH_VGYY
\GR\KOZKS7]OZN
HXGQKXKRKGYK\GR\K
OZKS9
RU]XGTMKUVKXGZKY
8KVRGIKJKLKIZO\K
\GR\K
RU]XGTMKOTUVKXGZO\K
/TZKXINGTMKSUZUXYNOLZ
\GR\KOZKS8]OZN
HXGQKXKRKGYK\GR\K
OZKS9
RU]XGTMKUVKXGZKY
8KVRGIKJKLKIZO\K
\GR\K
RU]XGTMKOTUVKXGZO\K
)NKIQJXO\KSUJK
ZUMMRKY]OZIN9KK
8KVGOXYKIZOUT
HGJ
8KVRGIKZUMMRKY]OZIN
UQ
)NKIQJXO\KXKYOYZKXYOT
VRGZLUXSIUTZXURHU^
9KKXKVGOXYKIZOUT
HGJ
UQ
6UYYOHRKJKLKIZO\KJXO\K
SGTOLURJUXJXO\K
SGTOLURJIUSVUTKTZ
6RKGYKIUTY[RZ-KTOK
/TJ[YZXOKYYKX\OIK
JKVGXZSKTZ
8KVRGIKJKLKIZO\K
XKYOYZKXY
5 - 60
Genie Z-45/22
Chart 35
Traction
Function
Inoperative
'T_Z_VKULZXGIZOUT
VXUHRKSIUTY[RZ-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
Genie Z-45/22
5 - 61
Chart 36
Machine Will
Not Drive At
Full Speed
Be sure all other
functions operate
normally.
Be sure the freewheel valve is
closed on the drive
pump.
5 - 62
=OZNHUUSL[RR_YZU]KJ
INKIQ:(LUX
IUTZOT[OZ_ZUMXU[TJ
L[RR
8KVGOXUXXKVRGIKHUUS
IUTZOT[OZ_ ROLZJXO\KROSOZY]OZINUX
HUUSK^ZKTJROSOZ
Y]OZIN
TUIUTZOT[OZ_
=OZNHUUSL[RR_YZU]KJ
INKIQNUXYKVU]KX
ROSOZKXHUGXJZKXSOTGR
LUXIUTZOT[OZ_ZUMXU[TJ
5XGTMK]OXKYNUXZKJ
L[RR
IUTZOT[OZ_ ZUMXU[TJXKVGOX
UXGTMK]OXKIOXI[OZLXUS
:(ZUNUXYKVU]KX
ROSOZKXHUGXJ
TUIUTZOT[OZ_
8KGJP[YZUXXKVRGIK
NUXYKVU]KXROSOZKX
HUGXJ9KK8KVGOX
YKIZOUT58IUTY[RZ
-KTOK/TJ[YZXOKY
9KX\OIK*KVGXZSKTZ
Genie Z-45/22
Chart 37
Machine
Drives At Full
Speed With
Platform
Raised or
Extended
Remove machine
from service
immediately.
Be sure boom lift
drive limit switch is
not being held down
or up.
Be sure wiring to
limit switches is
intact and show no
sign of tampering.
Be sure orange wire
(cable1) is properly
attached to
horsepower limiter.
8GOYKHUUSULLJXO\K
ROSOZY]OZINZ[XT
SGINOTKULLGTJINKIQ
IUTZOT[OZ_HKZ]KKT
MXU[TJGTJZKXSOTGR
UTNUXYKVU]KXROSOZKX
HUGXJ
L[RR
*OYIUTTKIZKRKIZXUTOI
IUTZOT[OZ_ JOYVRGIKSKTZIUTZXURRKX
+*)]OXKYUTJXO\K
V[SVSU\KJXO\K
IUTZXURRKXZUL[RRLUX]GXJ
VUYOZOUTGTJINKIQ
\URZGMKHKZ]KKT
ZKXSOTGRYGTJ
UTJXO\KIUTZXURRKX
ZU<
*KLKIZO\K9[TJYZXGTJ
JXO\KV[SV8KVRGIKUX
XKVGOXGZG[ZNUXO`KJ
9[TJYZXGTJXKVGOX
LGIOROZ_
ZU<
TUIUTZOT[OZ_
8KVRGIKNUXYKVU]KX
ROSOZKXHUGXJ
L[RR
IUTZOT[OZ_ 8KVGOXUVKTOTUXM]OXK
IOXI[OZLXUS:(ZU
NUXYKVU]KXROSOZKX
HUGXJZKXSOTGR
)NKIQIUTZOT[OZ_
HKZ]KKTMXU[TJ
GTJ:(
TUIUTZOT[OZ_
8KVGOXROSOZY]OZIN
]OXOTM58XKVRGIKHUUS
ROLZJXO\KROSOZY]OZIN58
XKVRGIKHUUSK^ZKTJ
JXO\KROSOZY]OZIN
Genie Z-45/22
5 - 63
Chart 38
Drive Enable
System is
Malfunctioning
*UTUZNURJZNKJXO\K
KTGHRKY]OZINGTJ
INKIQOLSGINOTK]ORR
JXO\KOTZNKYZU]KJ
VUYOZOUT]OZNHUUSU\KX
TUTYZKKX]NKKRY%
TU
=ORRNURJOTMZNKJXO\K
KTGHRKY]OZINGRRU]
HUUSZUJXO\KOT
YZU]KJVUYOZOUTU\KX
TUTYZKKX]NKKRY%
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5 - 64
Genie Z-45/22
Chart 39
Auxiliary
Functions
Inoperative
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Genie Z-45/22
5 - 65
5 - 66
Genie Z-45/22
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.
Malfunction
discovered
Troubleshoot
Determine
cause
problem
still exists
Return to
service
problem
solved
Inspect
and test
Perform
repair
Symbols Legend
Indicates the presence of a
hazard that will cause death or
serious injury.
wheels chocked
Genie Z-45/22
7-1
Platform Controls
1-1
Joystick Controllers
b
a
a
b
c
d
e
f
g
h
i
j
Genie Z-45/22
PLATFORM CONTROLS
2.50V DC
5.02V DC
25 to 29 seconds
4.33V DC
33 to 37 seconds
Genie Z-45/22
a
b
c
d
e
f
g
h
i
j
7-3
PLATFORM CONTROLS
5.01V DC
23 to 27 seconds
2.50V DC
7-4
Genie Z-45/22
PLATFORM CONTROLS
a
b
c
d
e
f
g
h
i
j
3.35V DC
6.26V DC
71 to 75 seconds
Genie Z-45/22
7-5
PLATFORM CONTROLS
1-2
Horsepower Limiter Board
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
7-6
Genie Z-45/22
PLATFORM CONTROLS
8.0V DC
9.0V DC
Genie Z-45/22
7-7
PLATFORM CONTROLS
1-3
Foot Switch
1-4
Resistors
Desired result
red to black
continuity (zero )
red to white
no continuity (infinite )
black to white
no continuity
Desired result
red to black
no continuity (infinite )
red to white
no continuity
black to white
continuity (zero )
7-8
Genie Z-45/22
PLATFORM CONTROLS
1-5
Toggle Switches
Test
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
terminal 3 to 4, 5 & 6
no continuity
terminal 4 to 5 & 6
no continuity
terminal 5 to 6
continuity
Center position
Left Position
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)
Genie Z-45/22
7-9
Platform Components
2-1
Platform
2-2
Platform Leveling Slave Cylinder
a
a
b
a
b
7 - 10
Genie Z-45/22
PLATFORM COMPONENTS
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.
Genie Z-45/22
7 - 11
PLATFORM COMPONENTS
a
b
c
a
b
c
d
clear hose
top bleed valve
bottom bleed valve
container
7 - 12
Genie Z-45/22
3-2
Primary Boom
a
a
b
Genie Z-45/22
7 - 13
b
a
b
c
7 - 14
a
b
c
upper mid-pivot
4x4x31 inch block
counterweight
wood block
tie-wrap
plastic cable track
Genie Z-45/22
Genie Z-45/22
7 - 15
3-3
Primary Boom Lift Cylinder
The lift cylinder raises and lowers the primary
boom.
b
c
a
b
c
upper mid-pivot
4x4x31 inch block
counterweight
7 - 16
Genie Z-45/22
a
b
a
b
pivot pin
10 to 12 inch rod
Genie Z-45/22
7 - 17
3-4
Extension Cylinder
a
b
c
d
a
b
c
d
b
c
upper mid-pivot
4x4x31 inch block
counterweight
7 - 18
Genie Z-45/22
3-5
Platform Leveling Master Cylinder
b
c
a
b
c
upper mid-pivot
4x4x31 inch block
counterweight
Genie Z-45/22
7 - 19
a
a
a
b
a
b
7 - 20
pivot pin
10 to 12 inch (30cm) rod
pivot pin
10 to 12 inch (30cm) rod
Genie Z-45/22
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.
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
pivot pin
10 to 12 inch (30 cm) rod
b
c
upper mid-pivot
4x4x31 inch block
counterweight
b
d
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
7 - 22
Genie Z-45/22
Genie Z-45/22
7 - 23
a
b
pivot pin
10 to 12 inch (30 cm) rod
7 - 24
Genie Z-45/22
Genie Z-45/22
7 - 25
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.
a
b
pivot pin
10 to 12 inch (30cm) rod
a
a
7 - 26
Genie Z-45/22
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.
Genie Z-45/22
7 - 27
6-1
RPM Adjustment
Refer to Maintenance Procedures, B-12,
Check and Adjust the Engine RPM.
6-2
Flex Plate
7 - 28
Genie Z-45/22
110
f
7-1
Governor Actuator
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 110
degree angle to the linkage rod.
Genie Z-45/22
7 - 29
7-3
Timing Adjustment
Complete information to perform this procedure is
available in the Ford LSG-423 2.3 Liter Industrial
Engine Service Manual (Ford number: 194-216).
Genie part number 29586.
7-4
Carburetor Adjustment
Complete information to perform this procedure is
available in the Ford LSG-423 2.3 Liter Industrial
Engine Service Manual (Ford number: 194-216).
Genie part number 29586.
7-2
Choke Adjustments
This engine is equipped with an electrically heated
automatic choke. The choke has a poppet valve to
enhance cold starting ability on LPG fuel.
Choke adjustments are affected
by climate. Richer adjustment will
be necessary in colder climates,
leaner adjustment in warmer
climates.
7-5
RPM Adjustment
See the scheduled maintenance procedure B-13,
Check and Adjust the Engine RPM.
7 - 30
lean
Genie Z-45/22
7-6
Flex Plate
Genie Z-45/22
7 - 31
7-7
Water Temperature and Oil
Pressure Switches
8-18 ft-lbs
11-24 Nm
Hex size
13/16 inch
230 F (112
Hex size
Oil pressure switch point
8-18 ft-lbs
11-24 Nm
1-1/16 inch
3-5 psi
0.21-0.34 bar
a
b
7 - 32
Genie Z-45/22
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.)
Genie Z-45/22
7 - 33
Ground Controls
8-1
Control Relays
Test
terminal 85 to 86
terminal 87a to 30
85 to 95
no continuity
(infinite )
continuity
(zero )
Desired result
terminal 87 to 30
Desired result
no continuity
(infinite )
continuity
(zero )
a
b
c
d
e
7 - 34
Genie Z-45/22
GROUND CONTROLS
8-2
Toggle Switches
8-4
Resistors
8-3
Wago Components
Genie Z-45/22
7 - 35
GROUND CONTROLS
8-5
Power Relay
Electrocution hazard. Contact with
hot or live circuits may result in
death or serious injury. Remove
all rings, watches and other
jewelry.
Test
Desired result
2 large posts
continuity
(zero )
Desired result
2 small posts
13 to 17
2 large posts
no continuity
(infinite )
no continuity
(infinite )
a
b
7 - 36
Genie Z-45/22
Hydraulic Pumps
5 Deutz Diesel models: Hold the manual
fuel shutoff valve counterclockwise to the
CLOSED position.
9-1
Lift/Steer Pump
How to Test the Lift/Steer Pump
1 Disconnect and plug the high pressure
hydraulic hose from the lift/steer pump.
Bodily injury hazard. Spraying
hydraulic oil can penetrate 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 Connect a 0 to 5000 psi (0 to 350 bar) pressure
gauge to the high pressure port.
3 Gasoline/LPG models: Remove the high
tension lead from the center of the ignition coil.
Electrocution hazard. Contact with
electrically charged circuits may
cause death or serious injury.
Remove all rings, watches and
other jewelry.
Genie Z-45/22
7 - 37
HYDRAULIC PUMPS
9-2
Drive Hydraulic Pump
open
closed
7 - 38
Genie Z-45/22
open
closed
HYDRAULIC PUMPS
Genie Z-45/22
7 - 39
Function Manifold
10-1
Function Manifold Components
Index
Schematic
No.
Description
3 position 4 way D01 valve ............... N ........... Platform rotate .................................. 30-35 in-lbs / 3-4 Nm
Item
Function
Torque
Counterbalance valve ........................ B ........... Platform level up ............................... 35-40 ft-lbs / 47-54 Nm
3 position 4 way D01 valve ............... O ........... Platform level .................................... 30-35 in-lbs / 3-4 Nm
Counterbalance valve ........................ BB ......... Turntable rotate right ........................ 35-40 ft-lbs / 47-54 Nm
Sandwich valve manifold ................... AAA ...... Turntable rotate counterbalance valves
3 position 4 way D01 valve ............... P ........... Turntable rotate ................................ 30-35 in-lbs / 3-4 Nm
3 position 4 way D01 valve ............... Q ........... Secondary boom up/down ................ 30-35 in-lbs / 3-4 Nm
3 position 4 way D01 valve ............... R ........... Primary boom up/down ..................... 30-35 in-lbs / 3-4 Nm
10
3 position 4 way D01 valve ............... S ........... Primary boom extend/retract ............ 30-35 in-lbs / 3-4 Nm
11
Counterbalance valve ........................ CC ........ Turntable rotate left .......................... 35-40 ft-lbs / 47-54 Nm
12
Counterbalance valve ........................ C ........... Platform level down .......................... 35-40 ft-lbs / 47-54 Nm
13
Check valve ....................................... K ........... Turntable rotate differential sensing ............................ 11-13 ft-lbs / 15-18 Nm
14
Check valve ....................................... M .......... Primary and secondary boom differential sensing ............................ 11-13 ft-lbs / 15-18 Nm
15
Flow regulator valve .......................... Y ........... Primary boom/secondary boom ....... 10-12 ft-lbs / 14-16 Nm
16
Relief valve, 1200 psi (83 bar) .......... D ........... Primary boom extend ....................... 25-30 ft-lbs / 34-41 Nm
17
Relief valve, 1200 psi (83 bar) .......... F ........... Primary boom down .......................... 25-30 ft-lbs / 34-41 Nm
18
Relief valve, 1200 psi (83 bar) .......... E ........... Secondary boom down ..................... 25-30 ft-lbs / 34-41 Nm
19
Proportional solenoid valve ............... AA ......... Primary boom/secondary boom ....... 10-12 ft-lbs / 14-16 Nm
20
21
Normally closed poppet valve ........... J ............ Platform level .................................... 25-30 ft-lbs / 34-41 Nm
22
23
Flow regulator valve .......................... V ........... Platform level .................................... 10-12 ft-lbs / 14-16 Nm
24
Differential sensing valve .................. AC ........ All functions ....................................... 10-12 ft-lbs / 14-16 Nm
25
Flow regulator valve .......................... U ........... Platform rotate/jib boom ................... 10-12 ft-lbs / 14-16 Nm
26
Flow regulator valve .......................... W .......... Differential sensing circuit ................. 10-12 ft-lbs / 14-16 Nm
27
28
Relief valve, 2200 psi (152 bar) ........ AB ......... System relief ..................................... 35-40 ft-lbs / 47-54 Nm
29
Priority flow regulator valve ............... T ........... Steering ............................................. 10-12 ft-lbs / 14-16 Nm
30
Check valve ....................................... I ............ Platform rotate right differential sensing ............................ 11-13 ft-lbs / 15-18 Nm
31
Check valve ....................................... H ........... Platform rotate left differential sensing ............................ 11-13 ft-lbs / 15-18 Nm
32
Check valve ....................................... L ........... Platform level - differential sensing .. 11-13 ft-lbs / 15-18 Nm
7 - 40
Genie Z-45/22
FUNCTION MANIFOLD
10
11
12
13
14
15
32
31
30
16
29
17
28
18
27
19
20
21
26
25
24
23
Genie Z-45/22
22
7 - 41
FUNCTION MANIFOLD
Hex Size
Torque
Specifications
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
/8
10-2
Valve Adjustments - Function
Manifold
7 - 42
Genie Z-45/22
FUNCTION MANIFOLD
Specifications
Valve
Proportional solenoid valve
3 pos 4 way directional valve
Normally closed
poppet valve
Resistance
5
4.5
7
c
a
b
c
directional valves
proportional valves
function manifold
Genie Z-45/22
7 - 43
11-1
Hydraulic Tank
The primary functions of the hydraulic tank are to
cool, clean and deaerate the hydraulic fluid during
operation. This tank 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.
open
closed
7 - 44
Genie Z-45/22
11-2
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 secondary boom 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.
Genie Z-45/22
7 - 45
12-2
Rotation Bearing and Worm Drive
b
c
a
b
c
7 - 46
Genie Z-45/22
upper mid-pivot
4x4x31 inch block
counterweight
a
b
a
b
open
closed
Genie Z-45/22
7 - 47
b
a
b
forks
block
24 Place a safety strap around the upper midpivot, then secure the strap to the forklift
carriage.
7 - 48
Genie Z-45/22
e
d
a
c
b
a
b
c
d
e
f
"O" mark
outer bearing
inner bearing
dowel
red mark
rotation stop block
10
15
13
12
18
17
11
5
8
16
14
2
Specifications - torque
First rotation
Second rotation
Genie Z-45/22
95 ft-lbs 129 Nm
190 ft-lbs 258 Nm
7 - 49
20
22
13
7
16
12
11
23
17
15
18
24
14
5
21
10
19
Specifications - torque
First rotation
95 ft-lbs 129 Nm
Second rotation
7 - 50
Genie Z-45/22
13-1
Yoke and Hub
a
b
c
d
e
f
g
h
axle
pin retainer
king pin
yoke
hub
cotter and clevis pin
steering cylinder
tie rod
Genie Z-45/22
7 - 51
13-2
Steering Cylinders
7 - 52
Genie Z-45/22
13-3
Tie Rod
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
Genie Z-45/22
7 - 53
14-1
Yoke and Hub
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 - 54
Genie Z-45/22
block
torque hub
yoke
axle
lock-out wedge
chassis
14-3
Tie Rod
How to Remove the Tie Rod
Weldment
This procedure is the same as the 2WD
procedure. See repair procedure 13-3, How to
Remove the Tie Rod Weldment.
14-2
Steering Cylinders
How to Remove the Steering
Cylinder
This procedure is the same as the 2WD
procedure. See repair procedure 13-2, How to
Remove the Steering Cylinder.
Genie Z-45/22
7 - 55
7 - 56
Genie Z-45/22
Description
Schematic
Item
3 position 4 way DO1 valve .............. F ........... Steering ............................................. 30-35 in-lbs / 3-4 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
Genie Z-45/22
7 - 57
Hex Size
Torque
SAE No. 2
/8
50 in-lbs / 6 Nm
SAE No. 4
/16
13 ft-lbs / 18 Nm
SAE No. 6
/4
18 ft-lbs / 24 Nm
SAE No. 8
/16
50 ft-lbs / 68 Nm
SAE No. 10
/16
55 ft-lbs / 75 Nm
SAE No. 12
/8
75 ft-lbs / 102 Nm
16-2
Valve Adjustments
Specifications
Unloader valve
1900 psi
131 bar
a
a
7 - 58
Genie Z-45/22
17-2
Torque Hub
Specifications
Lug nut torque
Genie Z-45/22
7 - 59
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
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
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
Hex Size
Torque
SAE No. 2
/8
50 in-lbs / 6 Nm
SAE No. 4
/16
13 ft-lbs / 18 Nm
SAE No. 6
/4
18 ft-lbs / 24 Nm
SAE No. 8
/16
50 ft-lbs / 68 Nm
SAE No. 10
/16
55 ft-lbs / 75 Nm
SAE No. 12
/8
75 ft-lbs / 102 Nm
7 - 60
Genie Z-45/22
10
16
15
14
13
12
11
Genie Z-45/22
7 - 61
18-2
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 penetrate 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 - 62
Genie Z-45/22
Genie Z-45/22
7 - 63
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
Check valve ........................... K .................... RR check in forward ................... 35-40 ft-lbs / 47-54 Nm
Orifice 0.025 in (0.635 mm) ... 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
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 - 64
Schematic
Item
Function
Genie Z-45/22
Torque
10
11
12
13
14
24
23
22
21
15
20
19
18
17
16
Genie Z-45/22
7 - 65
Hex Size
19-2
Valve Adjustments
Torque
SAE No. 2
/8
50 in-lbs / 6 Nm
SAE No. 4
/16
13 ft-lbs / 18 Nm
SAE No. 6
/4
18 ft-lbs / 24 Nm
SAE No. 8
/16
50 ft-lbs / 68 Nm
SAE No. 10
/16
55 ft-lbs / 75 Nm
SAE No. 12
/8
75 ft-lbs / 102 Nm
7 - 66
Genie Z-45/22