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Genie Z-30/20N Z-30/20N RJ Z-34/22N Z-34/22DC Service Manual – PDF
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Description
Genie Z-30/20N Z-30/20N RJ Z-34/22N Z-34/22DC Service Manual – PDF DOWNLOAD
Language : English
Pages : 188
Downloadable : Yes
File Type : PDF
Table of Contents:
Genie Z-30/20N Z-30/20N RJ Z-34/22N Z-34/22DC Service Manual – PDF DOWNLOAD
Front Cover............................................................................................................................................................................ 1 Introduction .......................................................................................................................................................................... 2 Important Information.............................................................................................................................................................. 2 Find a Manual for this Model....................................................................................................................................................... 2 Revision History................................................................................................................................................................... 3 Serial Number Legend............................................................................................................................................................... 5 Safety Rules........................................................................................................................................................................... 6 Table of Contents...................................................................................................................................................................... 8 Specifications ........................................................................................................................................................................ 14 Machine Specifications............................................................................................................................................................. 14 Machine Component Weights.......................................................................................................................................................... 15 Performance Specifications......................................................................................................................................................... 16 Hydraulic Specification............................................................................................................................................................ 17 Hydraulic Component Specifications................................................................................................................................................. 20 Manifold Component Specifications.................................................................................................................................................. 20 Machine Torque Specifications...................................................................................................................................................... 21 Hydraulic Hose and Fitting Torque Specifications................................................................................................................................... 22 Torque Procedure................................................................................................................................................................... 23 SAE and Metric Fasteners Torque Charts............................................................................................................................................. 25 Scheduled Maintenance Procedures....................................................................................................................................................... 26 Pre-Delivery Preparation Report.................................................................................................................................................... 29 Maintenance Inspection Report...................................................................................................................................................... 31 Checklist A Procedures............................................................................................................................................................. 32 A-1 Inspect the Manuals and Decals............................................................................................................................................. 32 A-2 Perform Pre-operation Inspection........................................................................................................................................... 33 A-3 Perform Function Tests..................................................................................................................................................... 33 A-4 Perform 30 Day Service..................................................................................................................................................... 34 A-5 Grease the Turntable Rotation Bearing and Worm Drive Gear.................................................................................................................. 34 A-6 Replace the Drive Hub Oil.................................................................................................................................................. 35 Checklist B Procedures............................................................................................................................................................. 36 B-1 Inspect the Battery........................................................................................................................................................ 36 B-2 Inspect the Electrical Wiring.............................................................................................................................................. 37 B-3 Inspect the Tires, Wheels and Lug Nut Torque............................................................................................................................... 38 B-4 Confirm the Proper Brake Configuration..................................................................................................................................... 39 B-5 Check the Drive Hub Oil Level and Fastener Torque.......................................................................................................................... 39 B-6 Test the Ground Control Override........................................................................................................................................... 40 B-7 Test the Platform Self-leveling............................................................................................................................................ 40 B-8 Test the Drive Brakes...................................................................................................................................................... 41 B-9 Test the Drive Speed - Stowed Position..................................................................................................................................... 41 B-10 Test the Drive Speed - Raised or Extended Position........................................................................................................................ 42 B-11 Test the Alarm Package (if equipped)...................................................................................................................................... 43 B-12 Test the Turntable Rotation Stop.......................................................................................................................................... 44 B-13 Check the Electrical Contactors........................................................................................................................................... 44 B-14 Perform Hydraulic Oil Analysis............................................................................................................................................ 45 B-15 Test the Emergency Power System........................................................................................................................................... 45 Checklist C Procedures............................................................................................................................................................. 47 C-1 Grease the Platform Overload Mechanism (if equipped)....................................................................................................................... 47 C-2 Test the Platform Overload System (if equipped)............................................................................................................................ 47 Checklist D Procedures............................................................................................................................................................. 49 D-1 Check the Boom Wear Pads................................................................................................................................................... 49 D-2 Check the Free-wheel Configuration......................................................................................................................................... 50 D-3 Check the Turntable Rotation Bearing Bolts................................................................................................................................. 51 D-4 Replace the Drive Hub Oil.................................................................................................................................................. 52 D-5 Replace the Hydraulic Tank Return Filter Element........................................................................................................................... 52 D-6 Inspect for Turntable Bearing Wear......................................................................................................................................... 53 Checklist E Procedures............................................................................................................................................................. 54 E-1 Test or Replace the Hydraulic Oil.......................................................................................................................................... 54 E-2 Grease the Steer Axle Wheel Bearings....................................................................................................................................... 56 Repair Procedures...................................................................................................................................................................... 58 Platform Controls.................................................................................................................................................................. 60 1-1 Controllers................................................................................................................................................................ 60 Platform Components................................................................................................................................................................ 62 2-1 Platform Leveling Slave Cylinder........................................................................................................................................... 62 2-2 Platform Rotator........................................................................................................................................................... 63 2-3 Platform Overload System................................................................................................................................................... 64 Jib Boom Components................................................................................................................................................................ 67 3-1 Platform Overload System................................................................................................................................................... 67 3-2 Jib Boom Bell Crank (models without rotating jib boom)..................................................................................................................... 68 3-3 Jib Boom Bell Crank (models with rotating jib boom)........................................................................................................................ 69 3-4 Jib Boom Lift Cylinder..................................................................................................................................................... 71 Primary Boom Components............................................................................................................................................................ 72 4-1 Cable Track................................................................................................................................................................ 72 How to Repair the Primary Boom Cable Track................................................................................................................................. 72 4-2 Primary Boom............................................................................................................................................................... 73 How to Remove the Primary Boom............................................................................................................................................. 73 How to Disassemble the Primary Boom........................................................................................................................................ 75 4-3 Primary Boom Lift Cylinder................................................................................................................................................. 76 4-4 Primary Boom Extension Cylinder............................................................................................................................................ 78 4-5 Platform Leveling Master Cylinder.......................................................................................................................................... 80 Secondary Boom Components.......................................................................................................................................................... 81 5-1 Secondary Boom............................................................................................................................................................. 82 5-2 Secondary Boom Lift Cylinders.............................................................................................................................................. 87 Hydraulic Pump..................................................................................................................................................................... 90 6-1 Auxiliary and Function Pump................................................................................................................................................ 90 Manifolds.......................................................................................................................................................................... 91 7-1 Function Manifold Components............................................................................................................................................... 91 7-2 Valve Adjustments - Function Manifold...................................................................................................................................... 95 How to Adjust the System Relief Valve...................................................................................................................................... 95 How to Adjust the Primary Boom Down Relief Valve........................................................................................................................... 95 How to Adjust the Secondary Boom Down Relief Valve......................................................................................................................... 96 How to Adjust the Primary Boom Extend Relief Valve......................................................................................................................... 96 How to Adjust the Turntable Rotate Relief Valve............................................................................................................................ 97 7-3 Jib Boom and Platform / Jib Boom Rotate Manifold Components................................................................................................................ 98 7-4 Valve Coils................................................................................................................................................................100 How to Test a Coil Diode...................................................................................................................................................101 Turntable Rotation Components......................................................................................................................................................103 8-1 Turntable Rotation Hydraulic Motor.........................................................................................................................................103 Steer Axle Components..............................................................................................................................................................104 9-1 Hub and Bearings...........................................................................................................................................................104 How to Remove the Hub and Bearings.........................................................................................................................................104 How to Install the Hub and Bearings........................................................................................................................................104 Non-steer Axle Components..........................................................................................................................................................106 10-1 Motor Controller..........................................................................................................................................................106 Fault Codes............................................................................................................................................................................107 Fault Code Charts..................................................................................................................................................................109 Schematics.............................................................................................................................................................................112 Electrical Symbol Legend...........................................................................................................................................................113 Hydraulic Symbols Legend...........................................................................................................................................................114 Limit Switch Location Legend.......................................................................................................................................................115 Electrical Schematics – Options....................................................................................................................................................116 Power Cable Wiring Diagram.....................................................................................................................................................117 Drive Contactor Panel Wiring Diagram...........................................................................................................................................118 Manifold and Limit Switch Wiring Diagram.......................................................................................................................................121 LVI/BCI Option Wiring Diagram..................................................................................................................................................122 Work and Drive Lights Option...................................................................................................................................................125 CTE Option, (CE Models)........................................................................................................................................................126 Charger Interlock Option.......................................................................................................................................................129 Hydraulic Schematics...............................................................................................................................................................130 Hydraulic Schematic............................................................................................................................................................131 Electrical Schematics – ANSI / CSA / AS Models...................................................................................................................................132 Electrical Schematic, (ANSI / CSA / AS), (before serial numbers Z30N10-12119, Z34N10-8857 and Z3410-7774)......................................................................133 Ground Control Box Terminal Strip Wiring Diagram, (ANSI / CSA / AS), (before serial numbers Z3010-12119, Z34N10-8857 and Z3410-7774)...........................................134 Ground Control Box Terminal Strip Wiring Diagram, (ANSI / CSA / AS), (before serial numbers Z3010-12119, Z34N10-8857 and Z3410-7774)...........................................137 Ground Control Box Switch Panel Wiring Diagram, (ANSI / CSA / AS), (before serial numbers Z30N10-12119, Z34N10-8857 and Z3410-7774)............................................138 Platform Control Box Wiring Diagram, (ANSI / CSA / AS), (before serial numbers Z30N10-12119, Z34N10-8857 and Z3410-7774).......................................................141 Electrical Schematics – CE Models..................................................................................................................................................142 Electrical Schematic, (CE), (before serial numbers Z30N10-12119, Z34N10-8857 and Z3410-7774)...................................................................................143 Ground Control Box Terminal Strip Wiring Diagram, (CE), (before serial numbers Z30N10-12119, Z34N10-8857 and Z3410-7774).......................................................147 Ground Control Box Switch Panel Wiring Diagram, (CE), (before serial numbers Z30N10-12119, Z34N10-8857 and Z3410-7774).........................................................148 Platform Control Box Wiring Diagram, (CE), (before serial numbers Z30N10-12119, Z34N10-8857 and Z3410-7774)....................................................................151 Electrical Schematics – ANSI and CSA Models........................................................................................................................................152 Electrical Schematic, (ANSI / CSA), (from serial numbers Z30N10-12119, Z34N10-8857 and Z3410-7774 to Z30N13-14695, Z34N13-10622 and Z3413-9441 )...............................153 Electrical Schematic, (ANSI / CSA), (from Z30N13-14696, Z34N13-10623 and Z3413-9442 to Z30N14-15221, Z34N14-10983 and Z3414-9685)..............................................157 Ground Control Box Terminal Strip Wiring Diagram, (ANSI / CSA), (from serial numbers Z30N10-12119, Z34N10-8857 and Z3410-7774 to Z30N13-14695, Z34N13-10622 and Z3413-9441)....161 Ground Control Box Switch Panel Wiring Diagram, (ANSI / CSA), (from serial numbers Z30N10-12119, Z34N10-8857 and Z3410-7774)...................................................162 Platform Control Box Wiring Diagram, (ANSI / CSA), (from serial numbers Z30N10-12119, Z34N10-8857 and Z3410-7774)..............................................................167 Electrical Schematic, (ANSI / CSA), (from Z30N13-14696, Z34N13-10623 and Z3413-9442 to Z30N14-15221, Z34N14-10983 and Z3414-9685)..............................................168 Electrical Schematics – AS / CE Models.............................................................................................................................................170 Electrical Schematic, (AS / CE), (from serial numbers Z30N10-12119, Z34N10-8857 and Z3410-7774 to Z30N13-14695, Z34N13-10622 and Z3413-9441)...................................171 Electrical Schematic, (AS / CE), (from Z30N13-14696, Z34N13-10623 and Z3413-9442 to Z30N14-15221, Z34N14-10983 and Z3414-9685).................................................175 Ground Control Box Terminal Strip Wiring Diagram, (AS / CE), (from serial numbers Z30N10-12119, Z34N10-8857 and Z3410-7774 to Z30N13-14695, Z34N13-10622 and Z3413-9441).......179 Ground Control Box Switch Panel Wiring Diagram, (AS / CE), (from serial numbers Z30N10-12119, Z34N10-8857 and Z3410-7774 to Z30N13-14695, Z34N13-10622 and Z3413-9441).........180 Ground Control Box Terminal Strip Wiring Diagram, (AS / CE), (from serial numbers Z30N13-14696, Z34N13-10623 and Z3413-9442 to Z30N14-15221, Z34N14-10983 and Z3414-9685)......183 Platform Control Box Wiring Diagram, (AS / CE) (from serial numbers Z30N10-12119, Z34N10-8857 and Z3410-7774 to Z30N13-14695, Z34N13-10622 and Z3413-9441).....................185 Platform Control Box Wiring Diagram, (AS / CE) (from serial numbers Z30N13-14696, Z34N13-10623 and Z3413-9442 to Z30N14-15221, Z34N14-10983 and Z3414-9685.....................186 Back Cover.........................................................................................................................................................................188
S.S 04/24
