Technical Publications Z Service Manual. First Edition Part No

Transcription

1 Technicl Publictions Z Service Mnul First Edition Prt No

2 Introduction Service Mnul - First Edition Importnt Red, understnd nd obey the sfety rules nd operting instructions in the Genie Z-45/22 Operting Instruction Mnul before ttempting ny mintennce or repir procedure. This service mnul covers the Genie Z-45/22 2WD nd 4WD models introduced in This mnul provides detiled scheduled mintennce informtion for the mchine owner nd user. It lso provides troubleshooting nd repir procedures for qulified service professionls. Genie U.S.A. nd Cnd Telephone (206) Toll Free Fx (206) Telex Genie Europe Telephone (44) Fx (44) Bsic mechnicl, hydrulic nd electricl skills re required to perform most procedures. However, severl procedures require specilized skills, tools, lifting equipment nd suitble workshop. In these instnces, we strongly recommend tht mintennce nd repir be performed t Genie deler service center. Genie Industries hs endevored to deliver the highest degree of ccurcy possible. However, continuous improvement of our products is Genie policy. Therefore product specifictions re subject to chnge without notice. Reders re encourged to notify Genie of errors nd send in suggestions for improvement. All communictions will be crefully considered for future printings of this nd other mnuls. Plese write to the technicl publictions tem in cre of Genie Industries, PO Box 69, Redmond WA USA. If you hve ny questions, cll Genie Industries. Copyright 1992 by Genie Industries First Edition, October 1992 Genie is registered trdemrk of Genie Industries Registered Printed on recycled pper Printed in U.S.A. ii Genie Z-45/22 Prt No

3 Service Mnul - First Edition Section 1 - Sfety Rules Sfety Rules Dnger Filure to obey the instructions nd sfety rules in this mnul, nd the Genie Z-45/22 Operting Instruction Mnul will result in deth or serious injury. Mny of the hzrds identified in the operting instruction mnul re lso sfety hzrds when mintennce nd repir procedures re performed. Do Not Perform Mintennce Unless: You re trined nd qulified to perform mintennce on this mchine. You red, understnd nd obey: - mnufcturer s instructions nd sfety rules - employer s sfety rules - pplicble governmentl regultions You hve the pproprite tools, lifting equipment nd suitble workshop. Prt No Genie Z-45/22 iii

4 Section 1 - Sfety Rules Service Mnul - First Edition SAFETY RULES Personl Sfety Any person working on or round mchine must be wre of ll known sfety hzrds. Personl sfety nd the continued sfe opertion of the mchine should be your number one priority. Red ech procedure thoroughly. This mnul nd the decls, on the mchine, use signl words to identify the following: Indictes the presence of hzrd tht will cuse deth or serious injury. Indictes the presence of hzrd tht my cuse deth or serious injury. Indictes the presence of hzrd tht will or my cuse serious injury or dmge to the mchine. Indictes specil opertion or mintennce informtion. Workplce Sfety Be sure to keep sprks, flmes nd lighted tobcco wy from flmmble nd combustible mterils like bttery gses nd engine fuels. Alwys hve n pproved fire extinguisher within esy rech. Be sure tht ll tools nd working res re properly mintined nd redy for use. Keep work surfces clen nd free of debris tht could get into mchine components nd cuse dmge. Be sure tht your workshop or work re is well ventilted nd sfely nd dequtely illuminted. Be sure ny forklift, overhed crne or other lifting or supporting device is fully cpble of supporting nd stbilizing the weight to be lifted. Use only chins or strps tht re in good condition nd of mple cpcity. Be sure to wer protective eye wer nd other protective clothing if the sitution wrrnts it. Be wre of potentil crushing hzrds such s moving prts, free swinging or unsecured components, nd lifting or plcing lods. Alwys wer pproved steel-toed shoes. Be sure tht fsteners intended for one time use (i.e., cotter pins nd self-locking nuts) re not reused. These components my fil if they re used second time. Be sure to properly dispose of old oil or other fluids. Use n pproved continer. Plese be mindful of the environment. iv Genie Z-45/22 Prt No

5 Service Mnul - First Edition Tble of Contents Introduction Importnt Informtion... ii Section One Sfety Rules Generl Sfety Rules... iii Section Two Specifictions Mchine Specifictions Performnce Specifictions Hydrulic Specifictions Ford LSG 423 Engine Specifictions Kubot V1702-B Engine Specifictions Section Three Scheduled Mintennce Inspections Introduction Tble A Tble B Tble C Tble D Mintennce Inspection Report Section Four Scheduled Mintennce Procedures Introduction A-1 Inspect the Operting Instruction nd Sfety Mnuls A-2 Inspect the Decls nd Plcrds A-3 Inspect for Dmge, Loose or Missing Prts A-4 Check the Engine Oil Level A-5 Check the Engine Coolnt Level A-6 Check for Fuel Leks A-7 Check the Hydrulic Oil Level A-8 Check for Hydrulic Leks A-9 Check Tire Pressure Prt No Genie Z-45/22 v

6 Service Mnul - First Edition TABLE OF CONTENTS Section Four Scheduled Mintennce Procedures, continued A-10 Test the Pltform nd Ground Controls A-11 Test Auxiliry Power Opertion A-12 Test the Tilt Level Sensor A-13 Test the Limit Switches A-14 Replce the Engine Oil nd Filter A-15 Chnge the Engine Air Filter A-16 Drin the Fuel Filter/Wter Seprtor - Diesel Models B-1 Check the Engine Fn Belts B-2 Check the Rditor B-3 Check the Exhust System B-4 Check the Bttery B-5 Check the Hydrulic Reservoir Filter Condition Indictor B-6 Inspect Electricl Wiring B-7 Inspect the Tires nd Wheels B-8 Confirm Proper Brke Configurtion B-9 Check the Oil Level in the Torque Hubs B-10 Check the Engine Choke - Gsoline/LPG Models B-11 Check the Glow Plugs - Diesel Models B-12 Check nd Adjust the Engine Idle Mixture - Gsoline/LPG Models B-13 Check nd Adjust the Engine RPM B-14 Test the Key Switch B-15 Test the Emergency Stop Buttons B-16 Test the Ground Control Override B-17 Test the Oscillte Lock-out B-18 Test Pltform Self-leveling B-19 Test the Service Horn B-20 Test the Foot Switch B-21 Test the Engine Speed Select B-22 Test Fuel Select Opertion - Gsoline/LPG Models B-23 Test the Turntble Rottion Stop vi Genie Z-45/22 Prt No

7 Service Mnul - First Edition TABLE OF CONTENTS Section Four Scheduled Mintennce Procedures, continued B-24 Test the Drive Enble System B-25 Test the Drive Brkes B-26 Test Drive Speed - Stowed Position B-27 Test the Alrm Pckge (optionl equipment) C-1 Check the Primry Boom Wer Pds C-2 Check the Turntble Rottion Bering Bolts C-3 Check the Free-wheel Feture C-4 Grese the Worm Drive Ger C-5 Replce the Torque Hub Oil C-6 Replce the Hydrulic Reservoir Filter C-7 Replce the Drive Loop Hydrulic Filter C-8 Replce the Diesel Fuel Filter C-9 Replce the Gsoline Fuel Filter C-10 Replce the PCV Vlve - Gsoline/LPG Models C-11 Clen or Replce the Distributor Cp nd Rotor - Gsoline/LPG Models C-12 Replce the Sprk Plugs - Gsoline/LPG Models C-13 Check nd Adjust the Air/Propne Mixture - Gsoline/LPG Models C-14 Check nd Adjust the Ignition Timing - Gsoline/LPG Models D-1 Chnge The Hydrulic Oil D-2 Chnge or Recondition the Engine Coolnt D-3 Chnge the Fuel Lines D-4 Check Engine Vlve Clernce - Gsoline/LPG Models D-5 Check Engine Cylinder Compression - Gsoline/LPG Models D-6 Clen PCV Hoses, Tubes, nd Fittings - Gsoline/LPG Models D-7 Check the Engine Nozzle Injection Pressure - Diesel Models D-8 Check Injection Timing - Diesel Models D-9 Replce The Timing Belt - Ford Prt No Genie Z-45/22 vii

8 Service Mnul - First Edition TABLE OF CONTENTS Section Five Troubleshooting Flow Chrts Introduction Engine Will Not Crnk Over Engine Crnks But Will Not Strt - Gsoline/LPG Models Engine Crnks But Will Not Strt - Diesel Models Engine Choke Inopertive - Gsoline/LPG Models Engine Glow Plugs Inopertive - Diesel Models See B-11, Check The Glow Plugs Engine Will Not Strt On LPG, But Will Strt On Gsoline - Gsoline/LPG Models Engine Will Not Strt On Gsoline, But Will Strt On LPG - Gsoline/LPG Models Engine High Idle Inopertive - Gsoline/LPG Models Engine Low Idle Inopertive - Gsoline/LPG Models Engine High Idle Inopertive - Diesel Models Engine Low Idle Inopertive - Diesel Models All Functions Inopertive, Engine Strts nd Runs All Lift nd Steer Functions Inopertive, Drive Functions Opertionl Ground Controls Inopertive, Pltform Controls Operte Normlly Pltform Controls Inopertive, Ground Controls Operte Normlly Secondry Boom Up Function Inopertive Secondry Boom Down Function Inopertive Primry Boom Up Function Inopertive Primry Boom Down Function Inopertive Primry Boom Extend Function Inopertive Primry Boom Retrct Function Inopertive Turntble Rotte Function Inopertive Turntble Rotte Left Function Inopertive Turntble Rotte Right Function Inopertive All Pltform Leveling Functions Inopertive Pltform Level Up Function Inopertive Pltform Level Down Function Inopertive viii Genie Z-45/22 Prt No

9 Service Mnul - First Edition TABLE OF CONTENTS Section Five Troubleshooting Flow Chrts, continued 28 Pltform Rotte Left Function Inopertive Pltform Rotte Right Function Inopertive Oscillte Lock-out Function Inopertive Steer Left Function Inopertive Steer Right Function Inopertive All Drive Functions Inopertive, All Other Functions Operte Normlly Drive Forwrd Or Reverse Function Inopertive High Rnge Drive Function Inopertive Low Rnge Drive Function Inopertive Mchine Will Not Drive At Full Speed Mchine Drives At Full Speed With Pltform Elevted Drive Enble System Is Mlfunctioning Auxiliry Functions Inopertive Section Six Schemtics Introduction Electricl Symbol Legend Electricl Schemtic - Gsoline/LPG Models Ground Control Box Legend - Gsoline/LPG Models Rely Pnel Legend - Gsoline/LPG Models Pltform Control Box Legend - Gsoline/LPG Models Electricl Schemtic - Diesel Models Ground Control Box Legend - Diesel Models Rely Pnel Legend - Diesel Models Pltform Control Box Legend - Diesel Models Hydrulic Symbols Legend WD Hydrulic Schemtic WD Hydrulic Schemtic Prt No Genie Z-45/22 ix

10 Service Mnul - First Edition TABLE OF CONTENTS Section Seven Repir Procedures Introduction Pltform Controls 1-1 Joystick Controllers Horsepower Limiter Bord Foot Switch Resistors Toggle Switches Pltform Components 2-1 Pltform Pltform Leveling Slve Cylinder Pltform Rottor Primry Boom Components 3-1 Plstic Cble Trck Primry Boom Primry Boom Lift Cylinder Extension Cylinder Pltform Leveling Mster Cylinder Secondry Boom Components 4-1 Secondry Boom Secondry Boom Lift Cylinders Turntble Covers 5-1 Turntble Covers Kubot V1702-B Engine 6-1 Timing Adjustment Glow Plugs RPM Adjustment Flex Plte Wter Temperture nd Oil Pressure Switches Ford LSG 423 Engine 7-1 Governor Actutor x Genie Z-45/22 Prt No

11 Service Mnul - First Edition TABLE OF CONTENTS Section Seven Repir Procedures, continued 7-2 Choke Adjustments Timing Adjustment Crburetor Adjustment RPM Adjustment Flex Plte Wter Temperture nd Oil Pressure Switches Vcuum Switch Ground Controls 8-1 Control Relys Toggle Switches, See 1-5, Toggle Switches Wgo Components Resistors Rely Pnel 9-1 Control Relys Power Rely Hydrulic Pumps 10-1 Lift/Steer Pump Drive Hydrulic Pump Function Mnifold 11-1 Function Mnifold Components Vlve Adjustments Fuel nd Hydrulic Tnks 12-1 Hydrulic Reservoir Fuel Tnk Turntble Rottion Components 13-1 Rottion Hydrulic Motor Rottion Bering nd Worm Drive WD Steering Axle Components 14-1 Yoke nd Hub Steering Cylinders Prt No Genie Z-45/22 xi

12 Service Mnul - First Edition TABLE OF CONTENTS Section Seven Repir Procedures, continued 14-3 Tie Rod WD Steering Axle Components 15-1 Yoke nd Hub Steering Cylinders, See 14-2, Steering Cylinders Tie Rod, See 14-3, Tie Rod Oscillting Axle Components 16-1 Oscillting Axle Lock-out Cylinder Steer nd Oscillte Mnifold 17-1 Steer nd Oscillte Mnifold Components Vlve Adjustments Non-steering Axle Components 18-1 Drive Motor Torque Hub WD Drive Mnifold WD Drive Mnifold Components Vlve Adjustments WD Drive Mnifold WD Drive Mnifold Components Vlve Adjustments xii Genie Z-45/22 Prt No

13 Service Mnul - First Edition Section 2 - Specifictions Specifictions Mchine Specifictions Stowed dimension 2WD 4WD Length Width Rough terrin Industril Height Weight Ground clernce Pltform dimensions Length Width Opertionl dimensions Mximum plform height Mximum pltform rech Mximum up-nd-over clernce Mximum turret tilswing Wheelbse Minimum turning rdius, outside Minimum turning rdiius, inside 17 ft 8 1 /2 in 17 ft 10 3 /4 in 5.4m 5.45m 6 ft 8 1 /4 in 6 ft 4 5 /8 in 203.8cm 194.6cm 5 ft 9 5 /8 in 176.8cm 6 ft 6 in 7 ft 4 in 1.98m 2.23m lbs lbs 6287kg 6536kg 8 in 11 in 20.3cm 27.9cm 6 ft 6 ft 182.8cm 182.8cm 30 in 30 in 76.2cm 76.2cm 45 ft 45 ft 13.72m 13.72m 23 ft 23 ft 7m 7m 21 ft 7 in 21 ft 7 in 6.58m 6.58m 1 inch none 2.54cm 6 ft 3 in 6 ft 3 in 190.5cm 190.5cm 14 ft 4 in 14 ft 9 in 4.37m 4.49m 7 ft 6 ft 8 in 2.13m 2.03m Tires nd wheels Rough terrin Industril Wheel dimeter Wheel width Wheel lugs - 4WD Wheel lugs - 2WD Front Rer Lug nut torque Tire size Tire ply rting Tire contct re Overll tire dimeter Tire pressure - 2WD Fluid cpcities Fuel tnk Propne tnk Hydrulic tnk Hydrulic system (including tnk) 4WD 17.5 inches 14.5 inches 10.5 inches 7 inches 5/8-18 5/8-18 5/8-18 5/8-18 5/ ft-lbs 125 ft-lbs Nm Nm NHS LT 8 Tred 8 Sidewll 6 59 sq in 43.5 sq in 380sq cm 280sq cm 35.8 inches 28 inches 91cm 71cm 40 psi 100 psi 2.76 br 6.89 br 28 psi 1.93 br 15 gllons 56.8 liters 33.5 pounds 15.2kg 25 gllons 95 liters 30 gllons 114 liters Torque hubs 17 ounces 0.5 liters Continuous improvement of our products is Genie policy. Product specifictions re subject to chnge without notice. Turret rottion Pltform rottion Prt No Genie Z-45/22 2-1

14 Section 2 - Specifictions Service Mnul - First Edition SPECIFICATIONS Performnce Specifictions Hydrulic Specifictions Drive speeds, mximum 2WD 4WD Hydrulic fluid Dexron II equivlent Boom lowered, high rnge Boom lowered, low rnge Boom rised, high rnge Boom rised, low rnge 5.0 mph 4.8 mph 8.0km/h 7.7km/h 1.1 mph 0.9 mph 1.8km/h 1.4km/h or 5 feet or 4 feet in 3 sec. in 3 sec mph / 1km/h or 1 foot per second 0.4 mph / 0.65km/h or 0.59 feet per second Drive pump Type Displcement Mximum drive pressure Chrge pressure bi-directionl vrible displcement piston pump 0-25 gpm liters/second 3500 psi br 360 psi / 24.8 br Grdebility (stowed) 30% 40% Medium pressure filter 3 micron Boom function speeds mximum from pltform controls Medium pressure filter bypss pressure 50 psi / 345kP Boom extend 29 seconds Drive mnifold Boom retrct Primry boom lift Primry boom lower 25 seconds 27 seconds 35 seconds Motor shift/brke relief pressure 4WD front motor flow regultors 350 psi 24.1 br 3.0 gpm 11.4 liters/minute Secondry boom lift Secondry boom lower 25 seconds 25 seconds 4WD rer motor flow regultors 4.5 gpm 17.0 liters/minute Turntble rotte (359 ) 73 seconds Pltform rotte (180 ) 15 seconds Pltform level up 25 seconds Pltform level down 15 seconds Multiple function stowed to full rised 60 seconds Multiple function full lowered to stowed 60 seconds 2-2 Genie Z-45/22 Prt No

15 Service Mnul - First Edition Section 2 - Specifictions SPECIFICATIONS Front drive motors - 4WD models Steer/oscillte mnifold Displcement per revolution Rer drive motor Displcement per revolution Function pump Type Displcement Function circuit return line filter 2.1 cu in / 34.4cc High cu in / 45.9cc Low cu in / 2.5cc fixed displcement ger pump rpm 0.4 liters/second 10 micron with 25psi / 172kP bypss Sequencing vlve pressure Accumultor pre-chrge pressure Auxillry pump Type Displcement Auxillry pump relief pressure 1800 psi 1600 psi fixed displcement ger pump 0.85 gpm 3.2 liters/minute 2030 psi 138 br Function mnifold Function relief vlve pressure 2200psi 138 br Secondry down relief vlve pressure 1200 psi 83 br Primry down relief vlve pressure 1200 psi 83 br Steer/oscillte flow regultor 1.5 gpm 5.7 liters/minute Prt No Genie Z-45/22 2-3

16 Section 2 - Specifictions Service Mnul - First Edition SPECIFICATIONS Bolt Torque Specifictions Size Threds SAE Grde 5 Bolts SAE Grde 8 Bolts Torque - Dry Torque - Dry Torque - Dry Torque - Dry Torque - Dry inch-pounds foot-pounds Newton meters inch-pounds foot-pounds Torque - Dry Newton meters / / / / / / / / / Torque specifiction for lubricted bolts is 25% less thn dry torque specifiction for bolt size. 2-4 Genie Z-45/22 Prt No

17 Service Mnul - First Edition Section 2 - Specifictions SPECIFICATIONS Ford Engine LSG-423 Strter motor Displcement Number of cylinders Bore nd stroke Horsepower Firing order High engine speed Low engine speed Governing Compression pressure Vlve clernces Intke Exhust Lubriction System Oil pressure (operting 2150 rpm) Oil cpcity (including filter) Oil viscosity requirements Below 60 F / 15.5 C -10 to 90 F / -23 to 32 C bove -10 F / -23 C bove 25 F / -4 C 140 cu in / 2.3 liters x inches 96 x 79.4mm rpm rpm 1200 rpm Precision electronic psi of lowest cylinder must be t lest 75% of highest cylinder inches mm inches mm psi kP 5 qurts / 4.71 liters 5W W W - 40 or 10W W - 40 or 20W - 50 Norml engine crnking speed Current drw, norml lod 110 rpm 150A Current drw, mximum lod 460A Current drw, no lod Mximum circuit voltge drop (norml temp) Brush length, new Brush length, wer limit Brush spring tension Bolt torque through brush Brush mounting bolt torque Mximum commuttor runout Bttery Type Ampere hour Cold Crnking Ampere 70A 0.5V DC 0.50 inches / 12.7mm 0.25 inches / 6.35mm 40 ounces inch-pounds gm-cm foot-pounds kg-m inches / 0.127mm, Group 24 75A 875A Reserve 25A rte 125 minutes Fuel Pump Sttic pressure Minimum volume flow psi 1 pint / 473cc in 25 seconds Use oils meeting API clssifiction SF (lbeled SF/CC or SF/CD) s they offer improved wer protection. Prt No Genie Z-45/22 2-5

18 Section 2 - Specifictions Service Mnul - First Edition SPECIFICATIONS Ignition System Ignition sprk dvnce Ignition coil primry resistnce Ignition coil secondry resistnce Type Gp Coolnt cpcity Alterntor output Fn belt tension new used 10 BTDC Ω (75 F) Ω (75 F) Motorcrft AWSF inches mm 11.5 qurts/10.9 liters 35A, 14.5V foot-pounds foot-pounds Bolt torque specifictions Item / Size Torque Torque (ft-lbs) (Nm) Cylinder hed bolt / M-12 torque in sequence: first step second step Distributor clmp bolt / M-10 Distributor vcuum tube to mnifold dptor Exhust mnifold to cylinder hed bolt or nut / M-10 torque in sequence: first step second step Flywheel to crnkshft bolt / M Fuel pump to cylinder block / M-8 Intke mnifold to cylinder hed bolt or nut / M-8 Oil pressure sending unit to block Oil pn drin plug to pn / M-14 Oil pn to block / M Auxiliry shft ger bolt / M Oil filter insert to block Auxiliry shft thrust plte bolt / M Rocker rm cover to cylinder hed / M Belt tensioner (timing) pivot bolt / M Sprk plug to cylinder hed / M Belt tensioner (timing) djusting bolt / M Temperture sending unit to block / M Cmshft ger bolt / M-12 Cmshft thrust plte bolt / M-6 Crburetor to spcer stud / M-8 Crburetor spcer to mnifold bolt / M-8 Crnkshft dmper bolt / M Wter jcket drin plug to block Wter pump to block bolt Auxiliry shft cover bolt / M-6 Wter outlet connection bolt / M-8 Cylinder front cover bolt / M-6 Inner timing belt cover stud / M-8 Outer timing belt cover bolt / M Genie Z-45/22 Prt No

19 Service Mnul - First Edition Section 2 - Specifictions SPECIFICATIONS Kubot Engine V1702-B Thermostt Displcement Number of cylinders Bore nd stroke Horsepower Firing order Compression rtio Compression pressure High engine speed Low engine speed Governing Vlve clernce, cold Lubriction System Oil pressure Oil cpcity including filter cu in / liters x 3.23 inches 82 x 82mm rpm : psi br 2150 rpm 1200 rpm centrifugl bll mechnicl inches mm psi kP 9.5 qurts / 9 liters Beginning opening Full-open Strter motor Current drw, no lod Brush length, new Brush length, minimum Bttery Type Ampere hour Cold crnking mpere Reserve 25A rte Glow plug resistnce Fn belt tension F C 203 F / 95 C 90A in. / 19mm 0.5 in. / 12.7mm, Group 24 75A 875A 125 minutes 1.5Ω in / 7-9mm Bolt torque specifictions Item Torque Torque (ft-lbs) (Nm) Cylinder hed bolt Oil viscocity requirements 10W - 30 Fuel injector nozzle holder to cylinder hed Engine oil should be MIL-L-2104C or hve properties of API clssifiction CC/CD/CE grdes. Injection System Fuel injector retining nut to nozzle holder body Flywheel to crnkshft bolt Injection pump Injection pump pressure Injection timing Fuel requirement Bosch K Type 1991 psi / 1437 br 25 BTDC Diesel number 2-D Oil pressure sending unit to block Oil pn drin plug to pn Rocker rm cover to cylinder hed Coolnt cpcity 7.25 qurts / 6.9 liters Rocker rm mounting nuts Alterntor output 35A, 14V Temperture sending unit to block Prt No Genie Z-45/22 2-7

20 Section 2 - Specifictions Service Mnul - First Edition SPECIFICATIONS Bolt torque specifictions - continued Size - Stndrd ft-lbs Nm M-6 M-8 M-10 M-12 M-14 M-16 M-18 M Size - Grde 7 M-6 M-8 M-10 M-12 M-14 M-16 M-18 M Size - Grde 9 M-6 M-8 M-10 M-12 M-14 M-16 M-18 M Genie Z-45/22 Prt No

21 Service Mnul - First Edition Section 3 - Scheduled Mintennce Inspections Scheduled Mintennce Inspections Deler Service recommended Cold engine required Wrm engine required New prts required Tools re required About This Section There re two components to this section, mintennce tbles nd n inspection reporting form. Observe nd Obey: Mintennce inspections shll be completed by person trined nd qulified on the mintennce of this mchine. Scheduled mintennce inspections shll be completed dily, frequently (every 3 months), nnully nd every 2 yers s specified on the mintennce inspection report. Filure to properly complete ech inspection when required my result in deth, serious injury or substntil mchine dmge. Immeditely tg nd remove from service dmged or mlfunctioning mchine. Repir ny mchine dmge or mlfunction before operting mchine. Keep records on ll inspections for three yers. Mintennce Tbles The mintennce tbles provide summry informtion on the specific physicl requirements for ech inspection. Complete step-by-step instructions for ech scheduled mintennce procedure is provided in section 4, Scheduled Mintennce Detils. Mintennce Inspection Report The mintennce inspection report contins checklists for ech type of scheduled inspection. Dily inspection Use checklist A Frequent inspection (every 150 hours or three months) Use checklists A nd B Annul inspection Use checklists A, B nd C Two yer inspection Use checklists A, B, C nd D Mke copies of this form to use for ech inspection. Store completed forms for three yers. Prt No Genie Z-45/22 3-1

22 Section 3 - Scheduled Mintennce Inspections Service Mnul - First Edition Mintennce Tbles Deler Service recommended Cold engine required Wrm engine required New prts required Tools re required Tble A A-1 Inspect the Operting Instruction nd Sfety Mnuls A-2 Inspect the Decls nd Plcrds A-3 Inspect for Dmge, Loose or Missing Prts A-4 Check the Engine Oil Level A-5 Check the Engine Coolnt Level A-6 Check for Fuel Leks A-7 Check the Hydrulic Oil Level A-8 Check for Hydrulic Leks A-9 Check Tire Pressure A-10 Test the Pltform nd Ground Controls A-11 Test Auxiliry Power Opertion A-12 Test the Tilt Level Sensor A-13 Test the Limit Switches Every 100 hours, check for nd/or perform s necessry the engine mintennce procedures listed below. A-14 Replce the Engine Oil nd Filter A-15 Chnge the Engine Air Filter A-16 Drin the Fuel Filter/Wter Seprtor - Diesel Models 3-2 Genie Z-45/22 Prt No

23 Service Mnul - First Edition Section 3 - Scheduled Mintennce Inspections MAINTENANCE TABLES Deler Service recommended Cold engine required Wrm engine required New prts required Tools re required Tble B B-1 Check the Engine Fn Belts B-2 Check the Rditor B-3 Check the Exhust System B-4 Check the Bttery B-5 Check the Hydrulic Reservoir Filter Condition Indictor B-6 Inspect Electricl Wiring B-7 Inspect the Tires nd Wheels including lug nut torque B-8 Confirm Proper Brke Configurtion B-9 Check the Oil Level in the Torque Hubs B-10 Check the Engine Choke - Gsoline/LPG Models B-11 Check the Glow Plugs - Diesel Models B-12 Check nd Adjust the Engine Idle Mixture - Gsoline/LPG Models B-13 Check nd Adjust the Engine RPM B-14 Test the Key Switch B-15 Test the Emergency Stop Buttons B-16 Test the Ground Control Override B-17 Test the Oscillte Lock-out oscillting xle equipped models Prt No Genie Z-45/22 3-3

24 Section 3 - Scheduled Mintennce Inspections Service Mnul - First Edition MAINTENANCE TABLES Deler Service recommended Cold engine required Wrm engine required New prts required Tools re required Tble B, continued B-18 Test Pltform Self-leveling B-19 Test the Service Horn B-20 Test the Foot Switch B-21 Test the Engine Speed Select B-22 Test Fuel Select Opertion - Gsoline/LPG Models B-23 Test the Turntble Rottion Stop B-24 Test the Drive Enble System B-25 Test the Drive Brkes B-26 Test Drive Speed - Stowed Position B-27 Test the Alrm Pckge (optionl equipment) trvel lrm, descent lrm, flshing becon Tble C C-1 Check the Primry Boom Wer Pds C-2 Check the Turntble Rottion Bering Bolts C-3 Check the Free-wheel Feture C-4 Grese the Worm Drive Ger including turntble rottion bering C-5 Replce the Torque Hub Oil C-6 Replce the Hydrulic Reservoir Filter 3-4 Genie Z-45/22 Prt No

25 Service Mnul - First Edition Section 3 - Scheduled Mintennce Inspections MAINTENANCE TABLES Deler Service recommended Cold engine required Wrm engine required New prts required Tools re required Tble C, continued C-7 Replce the Drive Loop Hydrulic Filter C-8 Replce the Diesel Fuel Filter C-9 Replce the Gsoline Fuel Filter C-10 Replce the PCV Vlve - Gsoline/LPG Models C-11 Clen or Replce the Distributor Cp nd Rotor - Gsoline/LPG Models C-12 Replce the Sprk Plugs - Gsoline/LPG Models C-13 Check nd Adjust the Air/Propne Mixture - Gsoline/LPG Models C-14 Check nd Adjust the Ignition Timing - Gsoline/LPG Models Tble D D-1 Chnge the Hydrulic Oil includes clening the suction striners D-2 Chnge or Recondition the Engine Coolnt including ll coolnt hoses nd clmps D-3 Chnge the Fuel Lines D-4 Check Engine Vlve Clernce - Gsoline/LPG Models D-5 Check Engine Cylinder Compression - Gsoline/LPG Models D-6 Clen PCV Hoses nd Fittings - Gsoline/LPG Models D-7 Check the Engine Nozzle Injection Pressure - Diesel Models D-8 Check Injection Timing - Diesel Models D-9 Replce the Timing Belt - Ford Prt No Genie Z-45/22 3-5

26 Section 3 - Scheduled Mintennce Inspections Service Mnul - First Edition Mintennce Inspection Report Model Deler Service recommended Cold engine required Seril number Dte Hour meter Mchine owner Wrm engine required Inspected by (print) Inspector signture Inspector title Inspector compny New prts required Tools re required Instructions Mke copies of this pge to use for ech inspection. Select the pproprite checklist(s) for the type of inspection to be performed. Dily Inspection: A Frequent Inspection: A+B Annul Inspection: A+B+C 2 Yer Inspection: A+B+C+D Plce check in the pproprite box fter ech inspection procedure is completed. Use the mintennce tbles in this section nd the step-by-step procedures in section 4 to lern how to perform these inspections. If ny inspection receives n N, remove the mchine from use, repir nd re-inspect it. After repir, plce check in the R box. Legend Y = yes, cceptble N = no, uncceptble R = repired Comments Checklist A Y N R Refer to Tble A A-1 Opertion nd Sfety mnuls A-2 Decls nd plcrds A-3 Dmge, loose or missing prts A-4 Engine oil A-5 Engine coolnt A-6 Fuel leks A-7 Hydrulic oil A-8 Hydrulic leks A-9 Tire pressure A-10 Pltform nd ground controls A-11 Auxiliry power A-12 Tilt lrm A-13 Limit switches Perform every 100 hours: A-14 Chnge engine oil nd filter A-15 Chnge engine ir filter A-16 Drin fuel filter/wter seprtor-diesel Checklist B Y N R Refer to Tble B B-1 Fn belts B-2 Engine rditor B-3 Exhust system B-4 Bttery B-5 Hydrulic reservoir filter B-6 Electricl wiring B-7 Tires nd wheels B-8 Brke configurtion B-9 Drive torque hubs B-10 Engine choke-gsoline B-11 Glow plugs-diesel B-12 Idle mixture-gsoline B-13 Engine RPM B-14 Key switch B-15 Emergency Stop button B-16 Ground control override B-17 Oscillte lock-out B-18 Pltform leveling B-19 Service horn B-20 Foot switch B-21 Engine speed select B-22 Fuel select-gsoline B-23 Turntble rottion stop B-24 Drive enble system B-25 Drive brkes B-26 Drive speed B-27 Alrm pckge Checklist C Y N R Refer to Tble C C-1 Wer pds C-2 Turntble bolts C-3 Free-wheel configurtion C-4 Worm drive ger C-5 Drive torque hubs C-6 Hydrulic reservoir filter C-7 Drive loop hydrulic filter C-8 Fuel filter-diesel C-9 Fuel filter-gsoline C-10 PCV vlve-gsoline C-11 Distibutor cp-gsoline C-12 Sprk plugs C-13 Propne djustments C-14 Ignition timing-gsoline Checklist D Y N R Refer to Tble D D-1 Hydrulic oil D-2 Engine coolnt, hoses nd clmps D-3 Fuel lines nd clmps D-4 Engine vlve clernce -gsoline D-5 Cylinder compression D-6 PCV hoses nd fittings-gsoline D-7 Engine injection nozzle -diesel D-8 Injection timing-diesel D-9 Timing belt-ford 3-6 Genie Z-45/22 Prt No

27 Service Mnul - First Edition Section 4 - Scheduled Mintennce Procedures Scheduled Mintennce Procedures About This Section This section contins detiled procedures for ech scheduled mintennce inspection. Observe nd Obey: Mintennce inspections shll be completed by person trined nd qulified on the mintennce of this mchine. Scheduled mintennce inspections shll be completed dily, frequently (every 3 months), nnully nd every 2 yers s specified on the minentnce report. Filure to properly complete ech inspection when required my result in deth, serious injury or substntil mchine dmge. Immeditely tg nd remove from service dmged or mlfunctioning mchine. Repir ny mchine dmge or mlfunction before operting mchine. Keep records on ll inspections for three yers. Ech procedure includes description, sfety wrnings nd step-by-step instructions. Symbols Legend Indictes the presence of hzrd tht will cuse deth or serious injury. Indictes the presence of hzrd tht my cuse deth or serious injury. Indictes the presence of hzrd tht will or my cuse serious injury or dmge to the mchine. Indictes specil opertion or mintennce informtion. Indictes tht specific result is expected fter performing series of steps. Prt No Genie Z-45/22 4-1

28 Section 4 - Scheduled Mintennce Procedures Service Mnul - First Edition Tble A Procedures A-1 Inspect the Operting Instruction nd Sfety Mnuls Mintining the Operting Instruction nd Sfety mnuls in good condition is essentil to sfe mchine opertion. Mnuls re included with ech mchine nd should be stored in the box provided in the pltform. An illegible or missing mnul will not provide sfety nd opertionl informtion necessry for sfe operting condition. 1 Check to mke sure tht the Operting Instruction nd Sfety mnuls re present in the storge box in the pltform. 2 Exmine the pges of ech mnul to be sure tht they re legible nd in good condition. 3 Alwys return the mnuls to the storge box fter use. A-2 Inspect the Decls nd Plcrds Contct your Genie distributor or Genie Industries if replcement mnuls re needed. Mintining ll of the sfety nd instructionl decls nd plcrds in good condition is mndtory for sfe mchine opertion. Decls lert opertors nd ground personnel to the mny possible hzrds ssocited with using this mchine. They lso provide users with opertion nd mintennce informtion. An illegible decl will fil to lert personnel of procedure or hzrd nd could result in unsfe operting conditions. 2 Inspect ll decls for dmge or illegibility. Replce ny illegible decl immeditely. Contct your Genie distributor or Genie Industries if replcement decls re needed. A-3 Inspect for Dmge, Loose or Missing Prts Dily mchine condition inspections re essentil to sfe mchine opertion nd good mchine performnce. Filure to locte nd repir dmge, nd discover loose or missing prts my result in n unsfe operting condition. 1 Inspect the entire mchine for dmge nd improperly instlled or missing prts including: electricl components, wiring nd electricl cbles hydrulic hoses, fittings, cylinders nd mnifolds fuel tnks drive nd swing motors nd ger boxes boom components nd wer pds tires nd wheels engine nd relted components limit switches, lrms, horns nd becon nuts, bolts nd other fsteners crcks in welds or structurl components 1 Refer to the Decls section in the Operting Instructions nd use the decl list nd illustrtions to determine tht ll decls nd plcrds re in plce. 4-2 Genie Z-45/22 Prt No

29 Service Mnul - First Edition Section 4 - Scheduled Mintennce Procedures TABLE A PROCEDURES A-4 Check the Engine Oil Level Mintining proper engine oil level is essentil to good engine performnce nd service life. Operting the mchine t n improper oil level cn dmge engine components. Check the oil level with the engine off. 1 Check the oil level dipstick. Add oil s needed. Specifictions Ford Engine LSG 423 Lubriction System Oil cpcity Oil viscosity requirements below 60F / 15.5C -10 to 90F / -23 to 32C bove -10F / -23C bove 25F / -4C 5 qurts / 4.7 liters 5W-30 10W-30 10W-40 or 10W-50 20w-40 or 20W-50 Kubot Engine V1702-B Lubriction System Oil cpcity Oil viscosity requirements 9.5 qurts / 9 liters 10W-30 Engine oil should be MIL-L-2104C or hve the properties of AI clssifiction CC/CD/CE grdes. A-5 Check the Engine Coolnt Level Mintining engine coolnt t the proper level is essentil to engine life. Improper coolnt level will ffect the engines cooling cpbility nd dmge engine components. Dily checks will llow the inspector to identify drmtic chnges in coolnt level tht might indicte cooling system problems. 1 Check the fluid level in the coolnt recovery tnk. Add wter s needed. Result: The fluid level should be in the norml rnge. A-6 Check for Fuel Leks Filure to detect nd correct fuel leks will result in n unsfe condition. An explosion or fuel fire my cuse deth or serious injury. Engine fuels re combustible. Inspect the mchine in n open, well-ventilted re wy from heters, sprks, flmes nd lighted tobcco. Alwys hve n pproved fire extinguisher within esy rech. 1 Open the shutoff vlve on the liquid propne gs (LPG) tnk by turning it counterclockwise. 2 Perform visul inspection round the following res. An LPG detector my be necessry to locte propne leks. Gsoline/LPG models: LPG tnk, hoses nd fittings, solenoid shutoff vlve, LPG regultor, nd crburetor gsoline tnk, shutoff vlve, solenoid shutoff vlve, hoses nd fittings, fuel pump nd crburetor Diesel models: diesel tnk, shutoff vlve, solenoid shutoff vlve, hoses nd fittings, fuel pump, fuel filter/ wter seprtor, fuel injection pump, fuel injectors If fuel lek is discovered, keep ny dditionl personnel from entering the re nd do not operte the mchine. Repir the lek immeditely. Prt No Genie Z-45/22 4-3

30 Section 4 - Scheduled Mintennce Procedures Service Mnul - First Edition TABLE A PROCEDURES A-7 Check the Hydrulic Oil Level Mintining hydrulic oil t the proper level is essentil to mchine opertion. Improper hydrulic oil levels cn dmge hydrulic components. Dily checks llow the inspector to identify chnges in oil level tht might indicte the presence of hydrulic system problems. 1 Be sure tht the mchine is in the fully stowed position, then visully inspect the sight guge locted on the side of the hydrulic oil reservoir. Result: The hydrulic oil level should be within the top 2 inches (5cm) of the sight guge. Specifictions Hydrulic oil type Reservoir cpcity Dexron II equivlent 25 gllons / 95 liters Do not overfill ll cylinders ll vlve mnifolds elevte nd primry booms the underside of the chssis ground re under the mchine A-9 Check Tire Pressure This procedure does not need to be performed on mchines equipped with the fom-filled tire option. To sfegurd mximum stbility, chieve optimum mchine hndling nd minimize tire wer, it is essentil to mintin proper pressure in ll irfilled tires. 1 Check ech tire with n ir pressure guge nd dd ir s needed. A-8 Check for Hydrulic Leks Detecting hydrulic fluid leks is essentil to opertionl sfety nd good mchine performnce. Undiscovered leks cn develop into hzrdous situtions, impir mchine functions nd dmge mchine components. 1 Inspect for hydrulic oil puddles, dripping or residue on or round the following res: hydrulic reservoir fittings, hoses nd turntble surfce engine comprtment fittings, hoses, uxiliry power unit, min pump nd turntble surfce Specifictions 2WD model industril tire rough terrin tire 4WD model rough terrin tire LT 100 psi / 6.89 br NHS 40 psi / 2.76 br NHS 28 psi / 1.93 br 4-4 Genie Z-45/22 Prt No

31 Service Mnul - First Edition Section 4 - Scheduled Mintennce Procedures TABLE A PROCEDURES A-10 Test the Pltform nd Ground Controls Testing mchine functions nd the Emergency Stop buttons for mlfunctions is essentil for sfe mchine opertion. An unsfe working condition exists if ny function fils to operte properly or either Emergency Stop button fils to stop ll the mchine functions nd shut off the engine. Ech function should ctivte, operte smoothly nd be free of hesittion, jerking nd unusul noise. 1 Strt the engine from the ground controls, nd then operte ech mchine function through full cycle. Result: All mchine functions should ctivte nd operte smoothly. 2 Push in the Emergency Stop button to the off position. Result: No function should operte, the engine should stop. Diesel models: All functions should stop immeditely. The engine will shut off fter 2 or 3 seconds. 3 Strt the engine from the pltform controls, nd then operte ech mchine function through full cycle. Result: All mchine functions should ctivte nd operte smoothly. 4 Push in the Emergency Stop button to the off position. Result: No function should operte, the engine should stop. As sfety feture, selecting nd operting the ground controls cn override the pltform controls, including the Emergency Stop button. A-11 Test Auxiliry Power Opertion Detection of uxiliry power system mlfunctions is essentil for sfe mchine opertion. An unsfe working condition exists if the uxiliry powered functions do not operte in the event of min power loss. Auxiliry power is designed for short term emergency use only, nd excessive use will result in bttery drin nd pump dmge. Oscillting xle equipped mchines only: From the stowed position, uxiliry power cn not rise the boom bove the drive limit switch. Auxiliry power cn rise the boom if it is lredy rised bove the drive limit switch. 1 Turn the key switch to ground control nd pull out the ground control Emergency Stop button to the on position. 2 Simultneously hold the uxiliry power switch on while ctivting the following functions through prtil cycle: primry boom up/down extend nd retrct elevte up/down turntble rotte right/left Result: Ech function should operte smoothly. 3 Turn the key switch to pltform control. 4 At the pltform controls, pull out the Emergency Stop button to the on position, press down the foot switch nd repet step 2. Prt No Genie Z-45/22 4-5

32 Section 4 - Scheduled Mintennce Procedures Service Mnul - First Edition TABLE A PROCEDURES A-12 Test the Tilt Level Sensor The tilt sensor sounds n lrm in the pltform when the incline of the chssis exceeds 3. 1 Strt the engine from the pltform controls. 2 Open the engine side cover nd press down on one side of the tilt sensor. Result: After 1 second dely, the lrm in the pltform should sound. Select level test re. broken or missing rollers or rms missing fsteners loose wiring 2 Strt the engine from the ground controls. 3 Rise the primry boom bove the drive limit switch nd turn the mchine off. 4 Mnully ctivte the drive limit switch. drive limit switch A-13 Test the Limit Switches Detecting limit switch mlfunctions is essentil to sfe mchine opertion. The drive enble limit switch ctivtes signl light to inform the opertor tht the pltform is over the steering wheels, nd stops drive movement unless the drive enble override switch is used. The drive limit switch is used to restrict drive speed when the boom is rised nd signl the oscillte cylinder to extend the lock-out wedges (oscillting xle equipped mchines). Also, on oscillting xle equipped mchines, there re two limit switches to stop the boom from being rised unless the lock out wedges re extended. Improperly functioning limit switches will llow the boom to rise nd/or drive into n unsfe position. Drive Limit Switch 1 With the engine off nd the mchine in the stowed position, visully inspect the drive limit switch for the following: Result: The drive limit switch rm should move freely nd spring return to center. A distinct click should be felt nd herd. 5 Restrt the engine nd lower the boom into the fully stowed position. 6 Move the key switch to pltform control, nd then strt the engine from the pltform controls. 7 Slowly move the drive control hndle off center. Result: The mchine should move t norml drive speeds. 8 Rise the primry boom bove the drive limit switch. 9 Slowly move the drive control hndle off center. Result: The mchine should move t reduced drive speed. Specifictions Elevted position 2WD nd 4WD 1 foot / 0.3 meter per second 4-6 Genie Z-45/22 Prt No

33 Service Mnul - First Edition Section 4 - Scheduled Mintennce Procedures TABLE A PROCEDURES Drive Enble Limit Switch 1 With the engine off nd the mchine in the stowed position, visully inspect the drive enble limit switch for the following: broken or missing rollers or rms missing fsteners loose wiring 2 Mnully ctivte the drive enble limit switch. Oscillting Axle Limit Switches 1 With the engine off nd the mchine in the stowed position, visully inspect the oscillte lock-out switch for the following: b Oscillting xle limit switch limit switch b oscillte lock out wedge drive enble limit switch Result: The drive enble limit switch roller should move freely nd spring return to center. A distinct click should be felt nd herd. 3 Strt the engine from the pltform controls nd then swing the turntble to the left until the pltform is positioned over the left steer wheel. Result: The pltform over steer wheels indictor light should be on. Drive movement should stop until the drive enble override switch is ctivted. 4 Swing the turntble to the right until the pltform is positioned over the right steer wheel. Result: The pltform over steer wheels indictor light should be on. Drive movement should stop until the drive enble override switch is ctivted. broken or missing rollers or rms missing fsteners loose wiring 2 Strt the engine from the ground controls nd rise the boom bove the drive speed limit switch. Result: The oscilltion cylinder should extend the lock-out wedges. The boom should stop moving until the wedges re fully extended. Prt No Genie Z-45/22 4-7

34 Section 4 - Scheduled Mintennce Procedures Service Mnul - First Edition TABLE A PROCEDURES A-14 Replce the Engine Oil nd Filter Engine specifictions require tht this procedure be performed every 100 hours. Perform this procedure more often if dusty conditions exist or the mchine is subjected to extended low idle opertion. Periodic replcement of the engine oil nd filter is essentil to good engine performnce. Operting the mchine with n improper oil level or neglecting periodic oil nd filter chnges cn dmge engine components. A dily check of elpsed mchine hours ginst the hours noted on the oil filter will llow the inspector to nticipte nd perform oil nd filter chnges t the 100 hour intervl. Perform this procedure fter wrming the engine to norml operting temperture. Bewre of hot engine prts nd oil. Contct with hot engine oil nd/or engine prts my cuse severe burns. 1 Remove the oil filler cp locted on the vlve cover. 2 Pull the end of the oil drin hose out from under the engine. 3 Remove the plug from the end of the drin hose nd llow ll of the oil from the engine to drin into continer cpble of holding 3 gllons. 4 Re-instll the plug into the drin hose. 5 Use n oil filter wrench nd remove the filter. Ford models: Remove the 3 bolts from the engine pivot plte. Swing the engine pivot plte wy from the mchine to ccess the oil filter. 6 Apply thin lyer of oil to the new oil filter gsket. Then instll the filter nd tighten it securely by hnd. 7 Fill the engine with new oil per specifictions nd replce the filler cp. 8 Strt the engine from the ground controls. Allow the engine to run for 30 seconds nd then turn the engine off. 9 Check the oil filter nd the oil drin hose for leks. 10 Use n indelible ink mrker to write the dte nd number of hours from the hour meter on the oil filter. Ford Models: Swing the engine pivoy plte bck to its originl position nd replce the three retining bolts. 11 Check the engine oil level dipstick. Add oil if needed. b b pivot plte bolts oil drin hose 4-8 Genie Z-45/22 Prt No

35 Service Mnul - First Edition Section 4 - Scheduled Mintennce Procedures TABLE A PROCEDURES Specifictions Ford Engine LSG 423 Lubriction System Oil cpcity Oil viscosity requirements below 60F / 15.5C -10 to 90F / -23 to 32C bove -10F / -23C bove 25F / -4C 5 qurts / 4.7 liters 5W-30 10W-30 10W-40 or 10W-50 20W-40 or 20W-50 Kubot Engine V1702-B Lubriction System Oil cpcity Oil viscosity requirements 9.5 qurts / 9 liters 10W-30 Engine oil should be MIL-L-2104C or hve the properties of AI clssifiction CC/CD/CE grdes. A-15 Chnge the Engine Air Filter Engine specifictions require tht this procedure be performed every 100 hours. Perform this procedure more often if dusty conditions exist. Mintining the engine ir filter in good condition is essentil to good engine performnce nd service life. Filure to perform this procedure cn led to poor engine performnce nd component dmge. Perform this procedure with the engine off. 1 Remove the end cp from the ir clener cnister. Kubot models: Remove the ir clener cnister mounting strps then the end cp. 2 Remove the mounting fstener from the ir filter, nd then remove the ir filter. 3 Insert the new ir filter nd replce the mounting fsteners. 4 Replce the end cp on the cnister. Prt No Genie Z-45/22 4-9

36 Section 4 - Scheduled Mintennce Procedures Service Mnul - First Edition TABLE A PROCEDURES A-16 Drin the Fuel Filter/ Wter Seprtor - Diesel Models Engine specifictions require tht this procedure be performed every 100 hours, long with n oil nd filter chnge. Poor fuel qulity or very wet conditions my necessitte performing this procedure more often. Proper mintennce of the fuel filter/wter seprtor is essentil for good engine performnce. Filure to perform this procedure cn led to poor engine performnce nd component dmge. Perform this procedure with the engine off. Engine fuels re explosive. Perform this procedure in n open, well-ventilted re wy from heters, sprks, flmes nd lighted tobcco. Alwys hve n pproved fire extinguisher within esy rech. 1 Loosen the vent plug locted on the fuel filter/ wter seprtor hed. 2 Loosen the drin plug locted t the bottom of the bowl. Allow the wter to drin into continer until fuel strts to come out. Immeditely tighten the drin plug. 3 Tighten the vent plug nd clen up ny spills or wet surfces. If the fuel bowl is completely drined, you must prime the fuel filter/wter seprtor before strting the engine. Refer to C-8 in this section, Replce The Diesel Fuel Filter, for instructions on how to prime the fuel filter/ wter seprtor. 4 Strt the engine from the ground controls nd check the fuel filter/wter seprtor for leks. e d b c Fuel filter/wter sepertor hed bolt b filter bowl c drin plug d vent plug e seprtor hed 4-10 Genie Z-45/22 Prt No