Terex Genie Z-45/25, 25J IC Power, Deutz, Ford, Perkins Articulated Boom Lift Service Manual
337 pages · Publication 77809
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- Models
- Genie Z-45/25, 25J IC Power, Deutz, Ford, Perkins
- Serial coverage
- Deutz: from 21180 to 23040, Ford: from 21180 to 23189, Perkins: from 21180 to 23008
- Manual type
- Service Manual
- Pages
- 337
- Publication
- 77809
- Condition
- Brand new
What's inside
From the manual's own table of contents: 117 topics. See sample pages (PDF, 567 KB)
- Important Information
- General Safety Rules
- Machine Specifications
- Performance Specifications
- Hydraulic Specifications
- Manifold Component Specifications
- Ford LRG-425 EFI Engine Specifications
- Deutz F3L-1011F Engine Specifications
- Perkins 104-22 Engine Specifications
- Machine Torque Specifications
- Hydraulic Hose and Fitting Torque Specifications
- SAE and Metric Fastener Torque Chart
- Introduction
- Pre-Delivery Preparation
- Maintenance Inspection Report
- Perform Pre-operation Inspection
- Perform Function Tests
- Perform Engine Maintenance - Deutz Models
- Perform Engine Maintenance - Ford Models
- Perform Engine Maintenance - Perkins Models
- Check the High Pressure Hydraulic Filter Condition Indicator
- Test the Oscillate Axle (if equipped)
- Perform 30 Day Service
- Perform Engine Maintenance - Ford and Perkins Models
Show all 117 topics
- A-10 Replace the Fuel Filters - Ford Models
- A-11 Inspect the Fuel Filter/Water Separator - Diesel Models
- A-12 Check and Adjust the Engine RPM - Perkins Models
- A-13 Grease the Turntable Rotation Bearing and Rotate Gear
- A-14 Perform Engine Maintenance - Ford Models
- A-15 Perform Engine Maintenance - Perkins Models
- Inspect the Battery
- Inspect the Electrical Wiring
- Test the Key Switch
- Check the Exhaust System
- Check the Oil Cooler and Cooling Fins - Deutz Models
- Check the Lug Nut Torque (including the tires and wheels)
- Confirm the Proper Brake Configuration
- Check the Oil Level in the Drive Hubs
- B-10 Check and Adjust the Engine RPM - Ford and Deutz Models
- B-11 Test the Ground Control Override
- B-12 Check the Directional Valve Linkage
- B-13 Test the Platform Self-leveling
- B-14 Test the Engine Idle Select
- B-15 Test the Fuel Select Operation - Ford Models
- B-16 Test the Drive Brakes
- B-17 Test the Drive Speed - Stowed Position
- B-18 Test the Drive Speed - Raised or Extended Position
- B-19 Test the Alarm Package (if equipped)
- B-20 Perform Hydraulic Oil Analysis
- B-21 Replace the Fuel Filter/Water Separator Element - Perkins Models
- B-22 Replace the Fuel Filter Element - Perkins Models
- B-23 Perform Engine Maintenance - Deutz Models
- B-24 Perform Engine Maintenance - Ford Models
- B-25 Perform Engine Maintenance - Perkins Models
- Grease the Platform Overload Mechanism (if equipped)
- Test the Platform Overload Mechanism (if equipped)
- Check the Boom Wear Pads
- Check the Turntable Rotation Bearing Bolts
- Check the Free-wheel Configuration
- Replace the Drive Hub Oil
- Check and Adjust the Air/LPG Mixture - Ford Models
- Inspect for Turntable Bearing Wear
- Calibrate the Platform Overload System (if equipped)
- Replace the Hydraulic Filters
- Test or Replace the Hydraulic Oil
- Change the Fuel Hoses - Ford Models
- Grease the Steer Axle Wheel Bearings, 2WD Models
- ALC-500 Circuit Board
- Joysticks
- Platform Leveling Slave Cylinder
- Platform Rotator
- Jib Boom
- Jib Boom Lift Cylinder
- Cable Track
- Primary Boom
- Primary Boom Lift Cylinder
- Primary Boom Extension Cylinder
- Platform Leveling Master Cylinder
- Secondary Boom
- Secondary Boom Lift Cylinders
- RPM Adjustment - Ford and Deutz Models
- RPM Adjustment - Perkins Models
- Flex Plate
- Engine Fault Codes - Ford Models
- Lift/Steer Pump
- Drive Pump
- Function Manifold Components (before serial number 22050)
- Valve Adjustments - Function Manifold (before serial number 22050)
- Function Manifold Components (after serial number 22049)
- Valve Adjustments - Function Manifold (after serial number 22049)
- (before serial number 22050)
- (after serial number 22049)
- Turntable Rotation Manifold Components
- Directional Valve Manifold Components
- Drive Manifold Components, 2WD
- 8-10 Valve Adjustments, 2WD Drive Manifold
- 8-11 Drive Manifold Components, 4WD
- 8-12 Valve Adjustments, 4WD Drive Manifold
- Turntable Rotation Assembly
- 10-1 Hub and Bearings, 2WD Models
- 10-2 Oscillate Lock-out Cylinders
- Fault Codes - Control System
- Fault Codes - Ford Models
- Electrical Symbols Legend
- Hydraulic Symbols Legend
- Engine Harness (before serial number 22050)
- Engine Harness (after serial number 22049)
- Electrical Schematic, Z-45/25 (before serial number 22050)
- Electrical Schematic, Z-45/25 (after serial number 22049)
- Electrical Schematic, Z-45/25J (before serial number 22050)
- Electrical Schematic, Z-45/25J (after serial number 22049)
- CE models
- CE Models (after serial number 22049)
- Hydraulic Schematic, 2WD Models (before serial number 22050)
- Hydraulic Schematic, 2WD Models (after serial number 22049)
- Hydraulic Schematic, 4WD Models (before serial number 22050)
- Hydraulic Schematic, 4WD Models (after serial number 22049)
Inside this manual
Real pages from this service manual (337 pages). Open the sample pages (PDF, 567 KB)
- Specifications, page 21: Section 2 • Specifications
- Troubleshooting, page 111: Section 4 • Repair Procedures
- Diagram, page 326: Platform Control Box Wiring Diagram, Z-45/25J
- Foldout diagram, page 270: Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J, CE Models
Other manuals for this machine
Save 10% on 2 manuals, 15% on 3 or more. Other manuals for the Genie Z-45/25 are listed below. Editions cover different serial number ranges: check the serial coverage and tick only the ones that match your machine.
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This is a service manual
Here's how it compares to the other manual types.
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 337 pages
Quantity one is the manual described above.
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60-day returns
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Binder not included
Manuals over about 300 pages may need a standard 3-ring binder, which you can buy locally to keep the pages organized for shop use.
Other editions and similar models
Questions about model, serial number, engine coverage or contents? Contact us before purchasing and we'll help confirm it's the right manual. Please verify the manual type, machine model, serial number range and engine coverage before purchasing: manuals ordered in error carry a 20% restocking fee (return policy).