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Genie Z-34/22 Bi-Energy Power Service Manual 128907 – PDF DOWNLOAD
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Description
Genie Z-34/22 Bi-Energy Power Service Manual 128907 – PDF DOWNLOAD
Language : English
Pages : 287
Downloadable : Yes
File Type : PDF
Table of Contents:
Genie Z-34/22 Bi-Energy Power Service Manual 128907 – PDF DOWNLOAD
Serial Number Information....................................................................................... 3 Safety Rules.................................................................................................... 5 Table of Contents............................................................................................... 7 Specifications.................................................................................................. 15 Machine Specifications...................................................................................... 15 Performance Specifications.................................................................................. 15 Hydraulic Oil Specifications................................................................................ 17 Hydraulic Component Specifications.......................................................................... 18 Manifold Component Specifications........................................................................... 19 Machine Torque Specifications............................................................................... 19 Kubota Z482-E Engine........................................................................................ 20 Generator................................................................................................... 21 Generator Torque Secifications.............................................................................. 21 Hydraulic Hose and Fitting Torque Specifications............................................................ 22 SAE and Metric Fastener Torque Chart........................................................................ 23 Scheduled Maintenance Inspections............................................................................... 25 Pre-Delivery Preparation.................................................................................... 27 Maintenance Inspection Report............................................................................... 29 Checklist A Procedures...................................................................................... 31 A-1 Inspect the Manuals and Decals...................................................................... 31 A-2 Perform Pre-operation Inspection.................................................................... 32 A-3 Perform Function Tests.............................................................................. 32 A-4 Perform Engine Maintenance.......................................................................... 33 A-5 Check the Generator Belts and Pulleys............................................................... 33 A-6 Peform 30 Day Service............................................................................... 35 A-7 Perform Engine Maintenance.......................................................................... 35 A-8 Perform Engine Maintenance.......................................................................... 36 A-9 Perform Engine Maintenance.......................................................................... 36 A-10 Grease the Turntable Rotation Bearing and Worm Drive Gear.......................................... 37 A-11 Replace the Drive Hub Oil.......................................................................... 38 A-12 Perform Engine Maintenance......................................................................... 39 Checklist B Procedures...................................................................................... 40 B-1 Check the Exhaust System............................................................................ 40 B-2 Inspect the Batteries............................................................................... 40 B-3 Inspect the Electrical Wiring....................................................................... 42 B-4 Inspect the Tires, Wheels and Lug Nut Torque........................................................ 42 B-5 Confirm the Proper Brake Configuration.............................................................. 43 B-6 Check the Oil Level in the Drive Hubs............................................................... 43 B-7 Check the Glow Plugs................................................................................ 44 B-8 Check and Adjust the Engine RPM..................................................................... 45 B-9 Test the Ground Control Override.................................................................... 46 B-10 Test the Platform Self-leveling.................................................................... 46 B-11 Test the Engine Idle Select........................................................................ 47 B-12 Test the Drive Brakes.............................................................................. 48 B-13 Test the Drive Speed - Stowed Position............................................................. 48 B-14 Test the Drive Speed - Raised or Extended Position................................................. 49 B-15 Test the Alarm Package (if equipped)............................................................... 49 B-16 Test the Turntable Rotation Stop................................................................... 50 B-17 Check the Electrical Contactors.................................................................... 51 B-18 Inspect the Fuel and Hydraulic Tank Cap Venting Systems............................................ 51 B-19 perform Hydraulic Oil Analysis..................................................................... 52 B-20 Perform Engine Maintenance......................................................................... 53 Checklist C Procedures...................................................................................... 54 C-1 Grease the Platform Overload Mechanism (if equipped)................................................ 54 C-2 Test the Platform Overload System (if equipped)..................................................... 54 C-3 Clean the Fuel Tank................................................................................. 57 C-4 Perform Engine Maintenance.......................................................................... 58 C-5 Perform Engine Maintenance.......................................................................... 58 Checklist D Procedures...................................................................................... 59 D-1 Check the Primary Boom Wear Pads.................................................................... 59 D-2 Check the Turntable Rotation Bearing Bolts.......................................................... 59 D-3 Inspect for Turntable Bearing Wear.................................................................. 60 D-4 Check the Free-wheel Configuration.................................................................. 62 D-5 Replace the Drive Hub Oil........................................................................... 63 D-6 Replace the Hydraulic Tank Return Filter............................................................ 64 Checklist E Procedures...................................................................................... 65 E-1 Test or Replace the Hydraulic Oil................................................................... 65 E-2 Perform Engine Maintenance.......................................................................... 66 E-3 Grease the Steer Axle Wheel Bearings................................................................ 67 E-4 Perform Engine Maintenance.......................................................................... 68 Repair Procedures............................................................................................... 69 Platform Controls........................................................................................... 70 1-1 Controllers......................................................................................... 70 1-2 Diodes.............................................................................................. 72 1-3 Foot Switch......................................................................................... 72 1-4 Toggle Switches..................................................................................... 73 Platform Components......................................................................................... 74 2-1 Platform............................................................................................ 74 2-2 Platform Leveling Slave Cylinder.................................................................... 74 2-3 Platform Rotator.................................................................................... 75 2-4 Platform Overload System............................................................................ 77 Jib Boom Components......................................................................................... 79 3-1 Jib Boom............................................................................................ 79 3-2 Jib Boom Lift Cylinder.............................................................................. 80 Primary Boom Components..................................................................................... 81 4-1 Plastic Cable Track................................................................................. 81 4-2 Primary Boom........................................................................................ 81 4-3 Primary Boom Lift Cylinder.......................................................................... 84 4-4 Extension Cylinder.................................................................................. 86 4-5 Platform Leveling Master Cylinder................................................................... 87 Secondary Boom Components................................................................................... 88 5-1 Secondary Boom...................................................................................... 89 5-2 Secondary Boom Lift Cylinder........................................................................ 92 Kubota Z482-E Engine........................................................................................ 93 6-1 Timing Adjustment................................................................................... 93 6-2 Glow Plugs.......................................................................................... 93 6-3 Engine RPM.......................................................................................... 93 6-4 Engine Drive Pulley................................................................................. 93 6-5 Water Temperature and Oil Pressure Switches......................................................... 95 Generator................................................................................................... 96 7-1 Generator........................................................................................... 96 7-2 Generator Belts..................................................................................... 98 7-3 Generator Voltage Regulator......................................................................... 98 Ground Controls.............................................................................................101 8-1 Control Relays......................................................................................101 8-2 Toggle Switches.....................................................................................102 8-3 Wago® Components....................................................................................102 Hydraulic Pumps.............................................................................................103 9-1 Auxiliary Pump......................................................................................103 9-2 Function Pump.......................................................................................104 Manifolds...................................................................................................106 10-1 Function Manifold Comopnents (before serial number 1112)...........................................106 10-2 Function Manifold Components (after serial number 1111)............................................108 10-3 Valve Adjustments - Function Manifold..............................................................110 10-4 Jib Boom / Platform Rotate Manifold Components (before serial number 2006).........................114 10-5 Jib Boom / Platform Rotate Manifold Components (after serial number 2005)..........................115 10-6 Steer/Brake Manifold Components (before serial number 1112)........................................116 Fuel and Hydraulic Tanks....................................................................................117 11-1 Fuel Tank..........................................................................................117 11-2 Hydraulic Tank.....................................................................................118 Turntable Rotation Components...............................................................................119 12-1 Rotation Hydraulic Motor...........................................................................119 Steer Axle Components.......................................................................................120 13-1 Steer Axle Components..............................................................................120 13-2 Steer Cylinder.....................................................................................121 13-3 Tie Rod............................................................................................122 Non-steer Axle Components...................................................................................123 14-1 Drive Motor........................................................................................123 14-2 Drive Hub..........................................................................................123 Motor controller............................................................................................125 15-1 Motor Controller...................................................................................125 Troubleshooting Flow Charts.....................................................................................127 Fault Code Chart............................................................................................129 Chart 1 Engine Will Not Crank Over..........................................................................132 Chart 2 Engine Cranks Over But Will Not Start...............................................................135 Chart 3 Engine Glow Plugs Inoperative.......................................................................138 Chart 4 Engine High Idle Inoperative........................................................................140 Chart 5 Engine Low Idle Inoperative.........................................................................142 Chart 6 All Lift and Steer Functions Inoperative, Drive Function Operational (before serial number 1112)....143 Chart 7All Lift and Steer Functions Inoperative, Drive Function Operational (after serial number 1111)......144 Chart 8 Ground Controls Inoperative, Platform Controls Operate Normally.....................................145 Chart 9 Platform Controls Inoperative, Ground Controls Operate Normally.....................................146 Chart 10 Primary Boom Up Function Inoperative...............................................................149 Chart 11 Primary Boom Down Function Inoperative.............................................................152 Chart 12 Secondary Boom Up Function Inoperative.............................................................155 Chart 13 Secondary Boom Down Function Inoperative...........................................................158 Chart 14 Primary Boom Extend Function Inoperative...........................................................161 Chart 15 Primary Boom Retract Function Inoperative..........................................................164 Chart 16 Turntable Rotate Left Function Inoperative.........................................................167 Chart 17 Turntable Rotate Right Function Inoperative........................................................170 Chart 18 All Platform Leveling Functions Inoperative........................................................173 Chart 19 Platform Level Up Function Inoperative.............................................................174 Chart 20 Platform Level Down Fuction Inoperative............................................................177 Chart 21 Platform Rotate Left Function Inoperative..........................................................180 Chart 22 Platform Rotate Right Inoperative..................................................................183 Chart 23 Jib Boom Up Function Inoperative...................................................................186 Chart 24 Jib Boom Down Function Inoperative.................................................................189 Chart 25 Steer Left Function Inoperative (before serial number 1112)........................................192 Chart 26 Steer Right Function Inoperative (before serial number 1112).......................................194 Chart 27 Steer Left Function Inoperative (after serial number 1111).........................................196 Chart 28 Steer Right Function Inoperative (after serial number 1111)........................................198 Chart 29 All Drive Functions Inoperative, All Other Functions Operate Normally..............................200 Chart 29A Motor Controller Fault Code 21: Throttle Fault....................................................202 Chart 29B Motor Controller Fault Code 32: Main Contactor welded.............................................203 Chart 29C Motor Controller Fault Code 34: Missing Main Contactor Or Main Contactor Did Not Close............204 Chart 30 Brake Release Function Inoperative.................................................................206 Chart 31 Traction Function Inoperative......................................................................208 Chart 32 Machine Will Not Drive At Full Speed...............................................................209 Chart 33 Machine Drives At Full Speed With Platform Raised Or Extended......................................211 Chart 34 Drive Enable System Inoperative....................................................................212 Chart 35 Auxiliary Functions Inoperative....................................................................214 Schematics......................................................................................................217 Electrical Components.......................................................................................218 Electrical Symbols Legend...................................................................................220 Abbreviation Legend.........................................................................................221 Hydraulic Symbols Legend....................................................................................222 Electrical Schematic (before serial number 1468)............................................................224 Electrical Schematic (from serial number 1468 to 3214)......................................................228 Electrical Schematic (from serial number 3215 to 3577)......................................................232 Electrical Schematic (from serial number 3578 to 4799)......................................................236 Ground Control Box Wiring Diagram (before serial number 1468)...............................................240 Ground Control Box Wiring Diagram (from serial number 1468 to 3214).........................................241 Ground Control Box Wiring Diagram (from serial number 3215 to 3577).........................................244 Ground Control Box Wiring Diagram (from 3578 to 4799).......................................................245 Platform Control Box Wiring Diagram (before serial number 1468).............................................248 Platform Control Box Wiring Diagram (from serial number 1468 to 1786).......................................249 Platform Control Box Wiring Diagram (from serial number 1787 to 2097).......................................252 Platform Control Box Wiring Diagram (from serial number 2098 to 3577).......................................253 Platform Control Box Wiring Diagram (from serial number 3578 to 4799).......................................255 Power Cable Wiring Diagram (before serial number 1468)......................................................258 Power Cable Wiring Diagram (from serial number 1468 to 4799)................................................259 Drive Contactor Panel Wiring Diagram (before serial number 1787)............................................262 Drive Contactor Panel Wiring Diagram (from serial number 1787 to 2060)......................................263 Drive Contactor Panel Wiring Diagram (from serial number 2061 to 4799)......................................265 Manifold and Limit Switch Wiring Diagram (before serial number 1112)........................................268 Manifold and Limit Switch Wiring Diagram (from serial number 1112 to 4799)..................................269 Engine Wiring Diagram.......................................................................................271 Load Sense Option Wiring Diagram (before serial number 2098)................................................274 Load Sense Option Wiring Diagram (from serial number 2098 to 3577)..........................................275 LVI / BCI Option Wiring Diagram.............................................................................277 Hydraulic Schematic (before serial number 1112).............................................................280 Hydraulic Schematic (from serial number 1112 to 2005).......................................................281 Hydraulic Schematic (from serial number 2006 to 3215).......................................................284 Hydraulic Schematic (from serial number 3216 to 4799).......................................................285
S.S 05/24
