Genie Z-45/25 & Z-45/25J Positive Air Shutdown Valve Parts and Service Supplement
Brand: Genie
Product Models: Z-45/25, Z-45/25J
Part Number: 161517 Rev B1
Publication Date: January 2016
Introduction
Important Safety Information: Read, understand, and obey all safety rules and operating instructions in the Genie Z-45/25 and Genie Z-45/25J Operator's Manual before attempting any maintenance or repair procedure.
This manual provides detailed parts and service information for qualified service professionals. Basic mechanical, hydraulic, and electrical skills are required for most procedures. However, some procedures require specialized skills, tools, lifting equipment, and a suitable workshop. For these, Genie strongly recommends maintenance and repair be performed at an authorized Genie dealer service center.
Technical Publications: Genie strives for accuracy but continuously improves products. Specifications are subject to change without notice. Readers are encouraged to report errors and suggest improvements for future printings.
Contact Us:
- Website: www.genielift.com
- Email: awp.techpub@terex.com
This Parts and Service Manual Supplement provides service parts information and electrical schematics for the Positive Air Shutdown System, which are not included in the standard parts or service manuals. Users should add this information to their existing manuals.
Copyright © 2011 Terex Corporation. All rights reserved. "Genie" and "Z" are registered trademarks of Terex South Dakota, Inc. Printed on recycled paper. Printed in U.S.A.
Revision History
| Revision | Date | Section | Procedure / Schematic Page / Description |
|---|---|---|---|
| A | 1/2013 | New release | |
| B | 5/2013 | Engine Chassis | Pg. 6, Pg. 7 Pg. 8, Pg. 9 |
| B1 | 1/2016 | Engine | Pg. 7 |
Reference Examples: Kubota Engine_Section 2_Specifications. A-6,B-3,C-7_Section 3_Maintenance Procedure. 3-2, 6-4, 9-1_Section 4_Repair Procedure. Fault Codes_Section 5. 6-35, 6-56, 6-104_Section 6_Schematic Page #.
Electronic Version: Click on any procedure or page number highlighted in blue to view the update.
Section 1: Service Parts
Engine Components
Diagram Description: An illustration of an engine assembly with numbered callouts indicating various parts. Key components include the main engine block, a positive air shutdown valve assembly (19), a solenoid (16, 17, 18), a circuit breaker (9), a relay (14), and various fasteners and hoses. A magnified view shows a sub-assembly with parts numbered 10 through 13.
| Item | Part No. | Description | Qty. |
|---|---|---|---|
| 1 | 101957 | Solenoid, 12V DC | 1 |
| 2 | 6357 | Hex Nut, 1/4 -20, GR 2 | 2 |
| 3 | 6638 | Flat Washer, 1/4 inch | 2 |
| 4 | 6090 | Screw - HHC, 1/4 -20 x 0.75 inch, GR 5 | 2 |
| 5 | 21130 | Clevis Yoke, 1/4 -28 | 1 |
| 6 | 21496 | Nut, 1/4 -28, GR 2 | 1 |
| 7 | 6888 | Screw - HHC, 1/4 -20 x 1 inch, GR 5 | 1 |
| 8 | 6091 | Nylock Nut, 1/4 -20 | 1 |
| 9 | 61211 | Circuit breaker, 15 Amp | 1 |
| 10 | 75041 | Screw, Phillips, 10-32 x 1 | 2 |
| 11 | 6146 | flat Washer, #10 | 4 |
| 12 | 6178 | Nylock nut, 10-32 | 3 |
| 13 | 49826 | Screw, Phillips, 10-32 x .625 | 1 |
| 14 | 61225 | Relay, 12 VDC, 70 Amp | 1 |
| 15 | 128079 | Gasket - Deutz Adapter | 1 |
| 16 | 25368 | Nut, Nylock, M8 x 1.25 | 3 |
| 17 | 33277 | Washer, Flat, M8 | 3 |
| 18 | 1256834 | Screw, SHC, M8-1.25 x 35, 12.9, Zag | 3 |
| 19 | 128065 | Valve - Positive Air Shutdown with Deutz Adapter | 1 |
Chassis Components
Diagram Description: Two diagrams are provided. The first shows a "Ground Control Box" with numbered components (1, 2). The second illustrates a larger chassis assembly, detailing the mounting of various components including a control box, fasteners (3, 4, 5, 6), and a controller module.
| Item | Part No. | Description | Qty. |
|---|---|---|---|
| - | 219681 | Wire Harness - Positive Air Shutdown | 1 |
| 1 | 52607 | Decal - Test | 1 |
| 2 | 128200 | Toggle Switch, SPDT 3 position, momentary (Test) (includes mounting fasteners) | 1 |
| - | 27246 | Toggle Switch Boot | |
| - | 128578 | Screw - PHPH, 6-32 X .025 | |
| 3 | 6091 | Nylock Nut, 1/4 -20 | 2 |
| 4 | 6638 | Flat Washer, 1/4 inch | 4 |
| 5 | 6884 | Screw - HHC, 1/4 -20 x 2.5 inches, GR 5 | 2 |
| 6 | 128067 | Positive Air Shutdown Controller | 1 |
| - | 128068 | Positive Air Shutdown System Software | |
| - | 110984 | Control Module | |
| - | 128069 | Control Module Label |
Section 2: Maintenance Procedures
Scheduled Maintenance Procedures
Observe and Obey:
- Maintenance inspections must be completed by a person trained and qualified on the maintenance of this machine.
- Scheduled maintenance inspections must be completed daily, quarterly, annually, and every 2 years as specified on the Maintenance Inspection Report.
- WARNING: Failure to properly complete each inspection when required may cause death, serious injury, or substantial machine damage.
- Immediately tag and remove from service a damaged or malfunctioning machine.
- Repair any machine damage or malfunction before operating the machine.
- Keep records of all inspections for three years.
- Unless otherwise specified, perform each procedure with the machine in the following configuration:
- Machine parked on a firm, level surface
- Boom in the stowed position
- Turntable rotated with the boom between the non-steering wheels
- Turntable secured with the turntable rotation lock
- Key switch in the off position with the key removed
- Wheels chocked
- All external AC power disconnected from the machine
About This Section: This section contains detailed procedures for each scheduled maintenance inspection, including descriptions, safety warnings, and step-by-step instructions.
Symbols Legend:
- ! DANGER: Safety alert symbol used to alert personnel to potential personal injury hazards. Obey all safety messages to avoid possible injury or death.
- DANGER: Red color indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
- WARNING: Orange color indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
- CAUTION: Yellow with safety alert symbol indicates a potentially hazardous situation which, if not avoided, may cause minor or moderate injury.
- NOTICE: Yellow without safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage.
- ⓘ Indicates that a specific result is expected after performing a series of steps.
- ✗ Indicates that an incorrect result has occurred after performing a series of steps.
Maintenance Inspection Report
Model: [Fill in Model]
Serial number: [Fill in Serial Number]
Date: [Fill in Date]
Hour meter: [Fill in Hour Meter]
Machine owner: [Fill in Machine Owner]
Inspected by (print): [Fill in Inspector Name]
Inspector signature: [Fill in Signature]
Inspector title: [Fill in Inspector Title]
Inspector company: [Fill in Inspector Company]
Instructions:
- Make copies of this report to use for each inspection. Store completed forms for three years.
- If any inspection receives an "N", tag and remove the machine from service, repair, and re-inspect it. After repair, place a check in the "R" box.
Legend:
- Y = yes, acceptable
- N = no, remove from service
- R = repaired
Comments: [Enter Comments Here]
Refer to the Genie Z-45/25 and Z-45/25J Service Manual for scheduled machine maintenance procedures. The following scheduled maintenance procedures will need to be performed in addition to regularly scheduled machine maintenance inspections as outlined in the Service Manual.
| Checklist | Y | N | R | |
|---|---|---|---|---|
| A - Rev A | A-3.1 Lubricate lever shaft | |||
| Perform every 100 hours: | A-9.1 Lubricate lever shaft |
A-3.1 Test the Automatic Engine Overspeed Control System
Genie specifications require that this procedure be performed daily or every 8 hours, whichever comes first. Regular testing of the automatic engine overspeed control system is essential to safe machine operation. Continued use of an improperly lubricated lever shaft could result in a positive air shutdown control system malfunction during an engine overspeed condition, potentially causing component damage.
Note: Perform this procedure with the machine on a firm, level surface.
- Pull out the red Emergency Stop Button to the 'on' position at both the ground and platform controls.
- Turn the key switch to ground control. Start the engine from the ground controls and allow it to idle.
- Locate the test toggle switch on the side of the ground control box. Move and hold the toggle switch to the 'test' position.
- Activate high idle (rabbit symbol ?).
- Result: The engine should shut off.
- Result: The engine does not shut off. Consult the Genie Service Department.
- Wait approximately 5 to 10 seconds for the solenoid valve to reset.
- Start the engine from the ground controls.
- Result: The engine should start and operate normally.
- Result: The engine does not start. Consult the Genie Service Department.
A-9.1 Lubricate the Lever Shaft
Genie specifications require that this procedure be performed every 100 hours or monthly, whichever comes first. Perform this procedure more often if dusty conditions exist. Lubrication of the lever shaft is essential to safe machine operation. Continued use of an improperly lubricated lever shaft could result in a positive air shutdown control system malfunction during an engine overspeed condition, potentially causing component damage.
- Locate the lever shaft on the shutdown valve assembly.
- Apply a liberal coating of grease to the shaft end surfaces on both sides of the valve. Refer to Illustrations 1 and 2.
Grease Specification: Chevron Ultra-duty grease, EP NLGI 2 (lithium based) or equivalent.
Illustration 1 Description: Shows a shutdown valve assembly (b) connected to a solenoid (a) and an air intake tube (d). The lever shaft (c) is clearly visible.
Illustration 2 Description: Another view of the shutdown valve assembly (b) with the lever shaft (c) and solenoid (a) highlighted.
Section 3: Schematics
Observe and Obey:
- Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine.
- Immediately tag and remove from service a damaged or malfunctioning machine.
- Repair any machine damage or malfunction before operating the machine.
Before Troubleshooting:
- Read, understand, and obey the safety rules and operating instructions in the appropriate operator's manual for your machine.
- Ensure that all necessary tools and test equipment are available and ready for use.
About This Section: This section covers Electrical Schematics.
WARNING: Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches, and other jewelry.
General Repair Process Description: A flowchart outlines the repair process: A 'Malfunction discovered' leads to 'Identify symptoms'. If the 'problem still exists', the process moves to 'Troubleshoot', then 'Perform repair', followed by 'Inspect and test'. If the 'problem solved' after inspection, the machine returns to service. If the 'problem still exists', it loops back to 'Troubleshoot'. An alternative path shows 'Malfunction discovered' -> 'Identify symptoms' -> 'problem solved' -> 'Return to service'.
System Wiring Diagram
Diagram Description: A schematic illustrating the electrical system. It shows connections between a TROMBETTA unit (with PULL COIL and HOLD COIL), a CONTROL MODULE (U18), a TEST SWITCH (TS74), a 12V DC battery, fuses (F11, CB8), and a relay (CR6). Various wire connections are labeled with J numbers, colors, and terminal points, indicating signal flow for functions like PULL COIL, HOLD COIL RELAY, RPM SIGNAL, and TEST SWITCH.
Ground Control Box Wiring Diagram
Diagram Description: A detailed wiring diagram for the ground control box. It depicts connections from the TROMBETTA unit, BATTERY, and CONTROL MODULE (U18). Various terminal bases (TB) and cables (e.g., 19/18 CABLES) are shown, with specific pins and functions labeled, such as "PRIMARY BOOM UP", "TURNTABLE ROTATE LEFT", "START ENGINE", "OIL PRESSURE", and "WATER TEMP". The diagram also shows internal wiring within the control module and terminal connections for various inputs and outputs.
