Terex Genie Z-45/25, Z-45/25J Telescopic Boom Lift Service Manual

Name: Terex Genie Z-45/25, Z-45/25J Telescopic Boom Lift Service Manual
Brand: MidWestTech
SKU: 52709
Price: 69.73 USD
Availability: InStock

440 pages · Publication 52709

$69.73

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Models: Genie Z-45/25, Z-45/25J
Serial coverage: from SN 9998 to 21179
Manual type: Service Manual
Pages: 440
Publication: 52709
Condition: Brand new

Terex Genie Z-45/25, Z-45/25J Telescopic Boom Lift Service Manual, publication 52709

What's inside

From the manual's own table of contents: 207 topics. See sample pages (PDF, 560 KB)

Search the contents

Important Information
General Safety Rules
Machine Specifications
Performance Specifications
Hydraulic Specifications
Ford LRG-425 EFI Engine Specifications
Deutz F3L 1011F Engine Specifications
Perkins 104-22 Engine Specifications
Hydraulic Hose and Fitting Torque Specifications
Power Source
Hydraulic System
Electrical System
Limit Switches
Machine Controls
Introduction
Maintenance Inspection Report
Inspect the Operator's and Safety Manuals
Inspect the Decals and Placards
Inspect for Damage and Loose or Missing Parts
Check the Engine Oil Level
Check the Engine Coolant Level - Liquid Cooled Models
Check for Fuel Leaks
Check the Hydraulic Oil Level
Check for Hydraulic Leaks

Show all 207 topics

Check the Tire Pressure
A-10 Test the Oscillate Axle (if equipped)
A-11 Test the Platform and Ground Controls
A-12 Test the Auxiliary Power Operation
A-13 Test the Tilt Sensor
A-14 Test the Limit Switches
A-15 Check the Engine Belt - Perkins Diesel Models
A-16 Inspect the Engine Air Filter Element
A-17 Replace the Fuel Filters - Ford Models
A-18 Inspect the Radiator - Perkins Models
A-19 Perform 30 Day Service
A-20 Replace the Engine Oil and Filter - Ford and Perkins Diesel Models
A-21 Inspect the Fuel Filter/Water Separator - Diesel Models
A-22 Check and Adjust the Engine RPM - Perkins Diesel Models
A-23 Check the Engine Belt - Ford Models
Check the Battery
Inspect the Electrical Wiring
Check the Radiator - Ford Models
Check the Exhaust System
Check the Hydraulic Return Filter Condition Indicator
Check the Oil Cooler and Cooling Fins - Deutz Diesel Models
Inspect the Tires and Wheels (including lug nut torque)
Confirm the Proper Brake Configuration
Check the Oil Level in the Drive Hubs
B-10 Check and Adjust the Engine RPM - Ford and Deutz Diesel Models
B-11 Test the Key Switch
B-12 Test the Emergency Stop Buttons
B-13 Test the Ground Control Override
B-14 Check the Directional Valve Linkage
B-15 Test the Platform Self-leveling
B-16 Test the Horn
B-17 Test the Foot Switch
B-18 Test the Engine Idle Select
B-19 Test the Fuel Select Operation - Ford Models
B-20 Test the Drive Enable System
B-21 Test the Drive Brakes
B-22 Test the Drive Speed - Stowed Position
B-23 Test the Drive Speed - Raised or Extended Position
B-24 Test the Alarm Package - Optional Equipment
B-25 Perform Hydraulic Oil Analysis
B-26 Replace the Hydraulic Tank Return Filter
B-27 Replace the Fuel Filter/Water Separator Element - Perkins Diesel Models
B-28 Replace the Fuel Filter Element - Perkins Diesel Models
B-29 Replace the Spark Plugs - Ford Models
B-30 Replace the Engine Air Filter Element
Check the Engine Belt- Deutz Diesel Models
Replace the Engine Oil and Filter - Deutz Diesel Models
Check the Engine Valve Clearances - Deutz Diesel Models
Change or Recondition the Engine Coolant - Liquid Cooled Models
Check the Engine Valve Clearances - Perkins Diesel Models
Replace the PCV Valve - Ford Models
Check the Boom Wear Pads
Check the Turntable Rotation Bearing Bolts
Check the Free-wheel Configuration
Grease the Turntable Rotation Bearing and Rotate Gear
Replace the Drive Hub Oil
Replace the Drive Loop Hydraulic Filter
Check and Adjust the Air/LPG Mixture - Ford Models
Replace the Diesel Fuel Filter/Water Separator - Deutz Diesel Models
Test or Replace the Hydraulic Oil
Change or Recondition the Engine Coolant - Ford Models
Change the Fuel Hoses
Check the Toothed Belt - Deutz Diesel Models
Check the Engine Valve Clearance - Ford Models
Check the Engine Cylinder Compression - Ford Models
Check the Fuel Injection Pumps and Injectors - Deutz Diesel Models
Replace the Timing Belt - Ford Models
Grease the Steer Axle Wheel Bearings, 2WD Models
Fault Codes
Engine Will Not Crank Over
Engine Cranks Over But Will Not Start - Ford Models
Engine Runs While Cranking Then Dies
Engine Cranks Over But Will Not Start - Diesel Models
Engine Will Not Start On LPG, But Will Start On Gasoline - Ford Models
Engine Will Not Start On Gasoline, But Will Start On LPG - Ford Models
Engine High Idle Inoperative - Ford Models
Engine Low Idle Inoperative - Ford Models
Engine High Idle Inoperative - Diesel Models
Engine Low Idle Inoperative - Diesel Models
All Functions Inoperative, Engine Starts and Runs
All Lift and Steer Functions Inoperative, Drive Functions Operational
Ground Controls Inoperative, Platform Controls Operate Normally
Platform Controls Inoperative, Ground Controls Operate Normally
Primary Boom Up Function Inoperative
Primary Boom Down Function Inoperative (before serial number 13099)
Primary Boom Down Function Inoperative (after serial number 13098)
Secondary Boom Up Function Inoperative
Secondary Boom Down Function Inoperative
Primary Boom Extend Function Inoperative
Primary Boom Retract Function Inoperative
Turntable Rotate Left Function Inoperative
Turntable Rotate Right Function Inoperative
All Platform Leveling Functions Inoperative
Platform Level Up Function Inoperative
Platform Level Down Function Inoperative
Platform Rotate Left Function Inoperative
Platform Rotate Right Function Inoperative
Jib Boom Up Function Inoperative, Z-45/25J Models
Jib Boom Down Function Inoperative, Z-45/25J Models
Steer Left Function Inoperative
Steer Right Function Inoperative
Oscillate Function Inoperative
All Drive Functions Inoperative, All Other Functions Operate Normally
Drive Forward Or Reverse Function Inoperative
Traction Function Inoperative
Machine Will Not Drive At Full Speed
Machine Drives At Full Speed With Platform Raised or Extended
Drive Enable System Is Malfunctioning
Auxiliary Functions Inoperative
Electrical Components
Electrical Symbols Legend
Abbreviation Legend
Ford LRG-425 EFI Engine Harness (before serial number 13099)
Ford LRG-425 EFI Engine Harness (after serial number 13098)
Electrical Schematic - Z-45/25 Ford Models (before serial number 13099)
(before serial number 13099)
Electrical Schematic, Z-45/25 Ford Models (after serial number 16303)
(after serial number 16303)
Electrical Schematic, Z-45/25J Ford Models (after serial number 16303)
Electrical Schematic, Z-45/25 Deutz Models (before serial number 13099)
Electrical Schematic, Z-45/25J Deutz Models (before serial number 13099)
Z-45/25 Deutz Models (after serial number 16303)
Electrical Schematic, Z-45/25J Deutz Models (after serial number 16303)
Z-45/25J Deutz Models (after serial number 16303)
Electrical Schematic, Z-45/25 Perkins Models (before serial number 16304)
(before serial number 16304)
Electrical Schematic, Z-45/25J Perkins Models (before serial number 16304)
Z-45/25J Perkins Models (before serial number 16304)
Electrical Schematic, Z-45/25 Perkins Models (after serial number 16303)
Electrical Schematic, Z-45/25J Perkins Models (after serial number 16303))
Z-45/25J Perkins Models (after serial number 16303)
Platform Control Box Wiring Diagram- Load Sensor Option, All Models
Hydraulic Symbols Legend
2WD Hydraulic Schematic
4WD Hydraulic Schematic
Joystick Controllers
Horsepower Limiter Board
Foot Switch
Toggle Switches
Platform
Platform Leveling Slave Cylinder
Platform Rotator
Jib Boom, Z-45/25J Models
Jib Boom Lift Cylinder, Z-45/25J Models
Jib Boom / Platform Rotate Manifold Components, Z-45/25J Models
Plastic Cable Track
Primary Boom
Primary Boom Lift Cylinder
Primary Boom Extension Cylinder
Platform Leveling Master Cylinder
Secondary Boom
Secondary Boom Lift Cylinders
Turntable Covers
RPM Adjustment
Flex Plate
Oil Temperature and Oil Pressure Gauges
Coolant Temperature and Oil Pressure Gauages
Timing Adjustment
Water Temperature and Oil Pressure Gauges
10-1 Control Relays
10-2 Toggle Switches, See 1-4, Toggle Switches
10-3 Wago® Components
10-4 Engine Fault Codes - Ford Models
11-1 Lift/Steer Pump
11-2 Drive Pump
12-1 Function Manifold Components
12-2 Valve Adjustments - Function Manifold
12-3 Turntable Rotation Manifold Components
12-4 Directional Valve Manifold Components
12-5 2WD Drive Manifold Components
12-6 Valve Adjustments, 2WD Drive Manifold
12-7 4WD Drive Manifold Components
12-8 Valve Adjustments, 4WD Drive Manifold
13-1 Fuel Tank
13-2 Hydraulic Tank
14-1 Rotation Hydraulic Motor
15-1 Yoke and Hub
15-2 Steering Cylinders
16-1 Yoke and Hub
16-2 Steering Cylinders, See 15-2, Steering Cylinders
17-1 Oscillating Axle Lock-out Cylinders
18-1 Drive Motor
18-2 Drive Hub

Inside this manual

Real pages from this service manual (440 pages). Open the sample pages (PDF, 559 KB)

Sample pages from the Terex Genie Z-45/25, Z-45/25J Telescopic Boom Lift Service Manual: Specifications, Diagram, Troubleshooting, Foldout diagram

Specifications, page 20: Section 2 • Specifications
Diagram, page 338: Platform Control Box Wiring Diagram-
Troubleshooting, page 398: Section 7 • Repair Procedures
Foldout diagram: Platform Control Box Wiring Diagram- Lift/Drive SelectOption,

This is a service manual

Here's how it compares to the other manual types.

This manual

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, 440 pages

Quantity one is the manual described above.

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Binder not included

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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).