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Genie Z-30/20N Service Manual 35532 – PDF DOWNLOAD
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Description
Genie Z-30/20N Service Manual 35532 – PDF DOWNLOAD
Language : English
Pages : 327
Downloadable : Yes
File Type : PDF
Table of Contents:
Genie Z-30/20N Service Manual 35532 – PDF DOWNLOAD
Safety Rules....................................................................................................................... 3 Table of Contents.................................................................................................................. 5 Specifications..................................................................................................................... 15 Machine Specifications......................................................................................................... 15 Performance Specifications..................................................................................................... 16 Hydraulic Specifications....................................................................................................... 17 Hydraulic Hose and Fitting Torque Specifications............................................................................... 18 Theory of Operation................................................................................................................ 19 Power Source................................................................................................................... 19 Hydraulic System............................................................................................................... 19 Electrical System.............................................................................................................. 19 Machine Controls............................................................................................................... 20 Scheduled Maintenance Procedures................................................................................................... 21 Maintenance Inspection Report.................................................................................................. 23 Checklist A Procedures......................................................................................................... 24 A-1 Inspect the Operator's and Safety Manuals.............................................................................. 24 A-2 Inspect the Decals and Placards........................................................................................ 24 A-3 Inspect for Damage and Loose or Missing Parts.......................................................................... 25 A-4 Check the Hydraulic Oil Level.......................................................................................... 25 A-5 Check for Hydraulic Leaks.............................................................................................. 26 A-6 Test the Platform and Ground Controls.................................................................................. 26 A-7 Test the Auxiliary Power Operation..................................................................................... 28 A-8 Test the Tilt Sensor................................................................................................... 28 A-9 Test the Limit Switches................................................................................................ 29 A-10 Perform 30 Day Service................................................................................................ 32 A-11 Grease the Turntable Rotation Bearing and Worm Drive Gear............................................................. 32 Checklist B Procedures......................................................................................................... 33 B-1 Check the Batteries.................................................................................................... 33 B-2 Inspect the Electrical Wiring.......................................................................................... 34 B-3 Inspect the Tires and Wheels (including lug nut torque)................................................................ 34 B-4 Confirm the Proper Brake Configuration................................................................................. 35 B-5 Check the Oil Level in the Drive Hubs.................................................................................. 35 B-6 Test the Key Switch.................................................................................................... 36 B-7 Test the Emergency Stop................................................................................................ 37 B-8 Test the Ground Control Override....................................................................................... 37 B-9 Test the Platform Self-leveling........................................................................................ 38 B-10 Test the Horn......................................................................................................... 38 B-11 Test the Foot Switch.................................................................................................. 39 B-12 Test the Drive Enable System.......................................................................................... 39 B-13 Test the Drive Brakes................................................................................................. 40 B-14 Test the Drive Speed - Stowed Position................................................................................ 41 B-15 Test the Drive Speed - Raised or Extended Position.................................................................... 42 B-16 Test the Alarm Package (if equipped).................................................................................. 42 B-17 Test the Turntable Rotation Stop...................................................................................... 43 B-18 Check the Electrical Contactors....................................................................................... 44 B-19 Check the Turntable Rotation Bearing Bolts............................................................................ 44 B-20 Replace the Hydraulic Tank Return Filter Element...................................................................... 46 B-21 Perform Hydraulic Oil Analysis........................................................................................ 47 Checklist C Procedures......................................................................................................... 48 C-1 Check the Primary Boom Wear Pads....................................................................................... 48 C-2 Check the Free-wheel Configuration..................................................................................... 48 C-3 Replace the Drive Hub Oil.............................................................................................. 49 C-4 Bleed the Platform Rotator............................................................................................. 50 Checklist D Procedures......................................................................................................... 51 D-1 Test or Replace the Hydraulic Oil...................................................................................... 51 D-2 Grease the Steer Axle Wheel Bearings................................................................................... 53 Repair Procedures.................................................................................................................. 55 Platform Controls.............................................................................................................. 56 1-1 Controllers............................................................................................................ 56 1-2 Diodes................................................................................................................. 64 1-3 Foot Switch............................................................................................................ 65 1-4 Toggle Switches........................................................................................................ 66 Platform Components............................................................................................................ 67 2-1 Platform............................................................................................................... 67 2-2 Platform Leveling Slave Cylinder....................................................................................... 68 2-3 Platform Rotator....................................................................................................... 69 Jib Boom Components............................................................................................................ 71 3-1 Jib Boom............................................................................................................... 71 3-2 Jib Boom Bell Crank (models without rotating jib boom)................................................................. 72 3-3 Jib Boom Rotator (models with rotating jib boom)....................................................................... 73 3-4 Jib Boom Lift Cylinder................................................................................................. 74 Primary Boom Components........................................................................................................ 76 4-1 Plastic Cable Track.................................................................................................... 76 4-2 Primary Boom........................................................................................................... 76 4-3 Primary Boom Lift Cylinder............................................................................................. 80 4-4 Extension Cylinder..................................................................................................... 82 4-5 Platform Leveling Master Cylinder...................................................................................... 84 Secondary Boom Components...................................................................................................... 86 5-1 Secondary Boom......................................................................................................... 87 5-2 Secondary Boom Lift Cylinder........................................................................................... 91 Ground Controls................................................................................................................ 94 6-1 Control Relays......................................................................................................... 94 6-2 Toggle Switches........................................................................................................ 96 6-3 Wago® Components....................................................................................................... 96 Hydraulic Pumps................................................................................................................ 97 7-1 Auxiliary Pump......................................................................................................... 97 7-2 Function Pump.......................................................................................................... 98 Manifolds......................................................................................................................100 8-1 Function Manifold Components (before serial number 3447)...............................................................100 8-2 Function Manifold Components (after serial number 3446)................................................................102 8-3 Valve Adjustments - Function Manifold..................................................................................106 8-4 Valve Coils............................................................................................................110 8-5 Jib Boom / Platform Rotate Manifold Components (before serial number 4083).............................................112 8-6 Jib Boom and Platform / Jib Boom Rotate Manifold Components (after serial number 4082).................................113 8-7 Steer / Brake Manifold Components (before serial number 3447)..........................................................114 Turntable Rotation Components..................................................................................................115 9-1 Turntable Rotation Hydraulic Motor.....................................................................................115 Steering Axle Components.......................................................................................................116 10-1 Yoke and Hub..........................................................................................................116 10-2 Steer Cylinder........................................................................................................118 10-3 Tie Rod...............................................................................................................118 Non-steering Axle Components...................................................................................................119 11-1 Drive Motor...........................................................................................................119 11-2 Drive Hub.............................................................................................................119 Motor Controller...............................................................................................................121 12-1 Motor Controller (after serial number 3446)...........................................................................121 Troubleshooting Flowcharts.........................................................................................................123 Fault Code Chart (after serial number 3446)....................................................................................125 Chart 1 All Functions Will Not Operate.........................................................................................129 Chart 2 Lift Pump Motor Will Not Operate.......................................................................................132 Chart 3 Auxiliary Pump Motor Will Not Operate..................................................................................138 Chart 4 All Functions Inoperative, Power Unit Starts and Runs..................................................................141 Chart 5 All Lift and Steer Functions Inoperative, Drive Function Operational...................................................142 Chart 6 Ground Controls Inoperative, Platform Controls Operate Normally........................................................145 Chart 7 Platform Controls Inoperative, Ground Controls Operate Normally (before serial number 3447)............................146 Chart 8 Platform Controls Inoperative, Ground Controls Operate Normally (after serial number 3446).............................150 Chart 9 Primary Boom Up Function Inoperative...................................................................................153 Chart 10 Primary Boom Down Function Inoperative................................................................................156 Chart 11 Secondary Boom Up Function Inoperative................................................................................159 Chart 12 Secondary Boom Down Function Inoperative..............................................................................162 Chart 13 Primary Boom Extend Function Inoperative (before serial number 5398)..................................................165 Chart 14 Primary Boom Extend Function Inoperative (after serial number 5397)...................................................169 Chart 15 Primary Boom Retract Function Inoperative.............................................................................172 Chart 16 Turntable Rotate Left Function Inoperative (before serial number 3447)................................................176 Chart 17 Turntable Rotate Left Function Inoperative (after serial number 3446).................................................180 Chart 18 Turntable Rotate Right Function Inoperative (before serial number 3447)...............................................183 Chart 19 Turntable Rotate Right Function Inoperative (after serial number 3446)................................................187 Chart 20 All Platform Leveling Functions Inoperative...........................................................................190 Chart 21 Platform Level Up Function Inoperative................................................................................192 Chart 22 Platform Level Down Function Inoperative..............................................................................197 Chart 23 Platform Rotate Left Function Inoperative (before serial number 4083).................................................202 Chart 24 Platform Rotate Left Function Inoperative (after serial number 4082)..................................................206 Chart 25 Platform Rotate Right Function Inoperative (before serial number 4083)................................................209 Chart 26 Platform Rotate Right Function Inoperative (after serial number 4082).................................................213 Chart 27 Jib Boom Up Function Inoperative (before serial number 4083)..........................................................216 Chart 28 Jib Boom Up Function Inoperative (after serial number 4082)...........................................................220 Chart 29 Jib Boom Down Function Inoperative (before serial number 4083)........................................................223 Chart 30 Jib Boom Down Function Inoperative (after serial number 4082).........................................................227 Chart 31 Jib Boom Rotate Left Function Inoperative (after serial number 4082)..................................................230 Chart 32 Jib Boom Rotate Right Function Inoperative (after serial number 4082).................................................233 Chart 33 Steer Left Function Inoperative (before serial number 3447)...........................................................236 Chart 34 Steer Left Function Inoperative (after serial number 3446)............................................................238 Chart 35 Steer Right Function Inoperative (before serial number 3447)..........................................................240 Chart 36 Steer Right Function Inoperative (after serial number 3446)...........................................................242 Chart 37 All Drive Functions Inoperative, all Other Functions Operate Normally (before serial number 3447).....................244 Chart 38 Brake Function Inoperative (before serial number 3447)................................................................250 Chart 39 All Drive Functions Inoperative, all Other Functions Operate Normally (after serial number 3446)......................254 Chart 39A Motor Controller Fault Code 21: Throttle Fault (after serial number 3446)............................................256 Chart 39B Motor Controller Fault Code 32: Main Contactor Welded (after serial number 3446).....................................257 Chart 39C Motor Controller Fault Code 34: Missing Main Contactor OR Main Contactor Did Not Close (after serial number 3446)....258 Chart 40 Brake Release Function Inoperative (after serial number 3446).........................................................261 Chart 41 Drive Forward Function Inoperative....................................................................................264 Chart 42 Drive Reverse Function Inoperative....................................................................................265 Chart 43 Machine Will Not Drive At Full Speed (before serial number 3447)......................................................266 Chart 44 Machine Will Not Drive At Full Speed (after serial number 3446).......................................................267 Chart 45 Machine Drives At Full Speed With Platform Raised Or Extended (before serial number 3447).............................269 Chart 46 Machine Drives At The Incorrect Speed With Platform Raised Or Extended (after serial number 3446).....................270 Chart 47 Drive Enable System Is Malfunctioning (before serial number 3447).....................................................271 Chart 48 Drive Enable System Is Malfunctioning (after serial number 3446)......................................................272 Chart 49 Remote Brake Release Inoperative......................................................................................273 Schematics.........................................................................................................................275 Electrical Components..........................................................................................................276 Load Sensor Option Diagram (before serial number 4083).........................................................................278 Load Sensor Option Diagram (from serial number 4083 to 4255)...................................................................279 Load Sensor Option Diagram (after serial number 4255)..........................................................................280 Power Cable Diagram (before serial number 3447)................................................................................282 Power Cable Diagram (after serial number 3446).................................................................................283 Electrical Symbols Legend......................................................................................................286 Electrical Schematic (before serial number 747)................................................................................288 Electrical Schematic (from serial number 747 to 3446)..........................................................................292 Electrical Schematic (from serial number 3447 to 4082).........................................................................296 Electrical Schematic (after serial number 4082)................................................................................300 Ground Control Panel Legend (before serial number 747).........................................................................303 Ground Control Panel Wiring Diagram (from serial number 747 to 3446)...........................................................305 Ground Control Panel Wiring Diagram (from serial number 3447 to 4082)..........................................................307 Ground Control Panel Wiring Diagram (after serial number 4082).................................................................309 Platform Control Box Wiring Diagram (before serial number 3447)................................................................311 Platform Control Box Wiring Diagram (from serial number 3447 to 4082)..........................................................313 Platform Control Box Wiring Diagram (after serial number 4082).................................................................315 Hydraulic Symbols Legend.......................................................................................................318 Hydraulic Schematic (before serial number 3447)................................................................................319 Hydraulic Schematic (from serial number 3447 to 4082)..........................................................................321 Hydraulic Schematic (from serial number 4083 to 5397)..........................................................................323 Hydraulic Schematic (after serial number 5397).................................................................................325
S.S 05/24
