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Genie Z-34/22 Bi-Energy Power Service Manual 139234 – PDF DOWNLOAD
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Genie Z-34/22 Bi-Energy Power Service Manual 139234 – PDF DOWNLOAD
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Description
Genie Z-34/22 Bi-Energy Power Service Manual 139234 – PDF DOWNLOAD
Language : English
Pages : 186
Downloadable : Yes
File Type : PDF
Table of Contents:
Genie Z-34/22 Bi-Energy Power Service Manual 139234 – PDF DOWNLOAD
Front Cover.......................................................................................... 1 Introduction Introduction............................................................................ 2 Important Information............................................................................ 2 Find a Manual for this Model..................................................................... 2 Revision History................................................................................. 3 Serial Number Legend............................................................................. 4 Section 1 Safety Rules............................................................................... 5 General Safety Rules............................................................................. 5 Table of Contents.................................................................................... 7 Specifications....................................................................................... 14 Machine Specifications........................................................................... 14 Performance Specifications....................................................................... 14 Hydraulic Specification.......................................................................... 15 Hydraulic Component Specifications............................................................... 17 Manifold Component Specifications................................................................ 17 Machine Torque Specifications.................................................................... 18 Machine Component Weights....................................................................... 18 Kubota Z482-E Engine Specifications.............................................................. 19 Generator Specifications......................................................................... 20 Hydraulic Hose and Fitting Torque Specifications................................................. 21 Torque Procedure................................................................................. 22 SAE and Metric Fasteners Torque Charts........................................................... 23 Scheduled Maintenance Procedures .................................................................... 24 Introduction..................................................................................... 24 Pre-Delivery Preparation Report.................................................................. 27 Maintenance Inspection Report.................................................................... 29 Maintenance Inspection Report.................................................................... 30 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 Perform 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 Battery...................................................................... 40 B-3 Inspect the Electrical Wiring............................................................ 42 B-4 Inspect the Tires, Wheels and Lug Nut Torque............................................. 43 B-5 Confirm the Proper Brake Configuration................................................... 43 B-6 Check the Drive Hub Oil Level and Fastener Torque........................................ 44 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).................................................... 50 B-16 Check the Electrical Contactors......................................................... 51 B-17 Inspect the Fuel and Hydraulic Tank Cap Venting Systems................................. 51 B-18 Perform Hydraulic Oil Analysis.......................................................... 52 B-19 Test the Emergency Power System......................................................... 53 B-20 Perform Engine Maintenance.............................................................. 54 Checklist C Procedures........................................................................... 55 C-1 Grease the Platform Overload Mechanism (if equipped)..................................... 55 C-2 Test the Platform Overload System - (if equipped)........................................ 55 C-3 Perform Engine Maintenance............................................................... 57 C-4 Perform Engine Maintenance............................................................... 57 Checklist D Procedures........................................................................... 58 D-1 Check the Boom Wear Pads................................................................. 58 D-2 Check the Turntable Rotation Bearing Bolts............................................... 58 D-3 Inspect for Turntable Bearing Wear....................................................... 59 D-4 Check the Free-wheel Configuration....................................................... 61 D-5 Replace the Drive Hub Oil................................................................ 62 D-6 Replace the Hydraulic Return Filter...................................................... 62 Checklist E Procedures........................................................................... 64 E-1 Test or Replace the Hydraulic Oil........................................................ 64 E-2 Grease the Steer Axle Wheel Bearings, 2WD Models......................................... 65 E-3 Perform Engine Maintenance............................................................... 67 E-4 Perform Engine Maintenance............................................................... 67 Repair Procedures.................................................................................... 68 Introduction..................................................................................... 68 Platform Controls................................................................................ 70 1-1 Controllers.............................................................................. 70 Boom Function Speed Controller Adjustments............................................... 70 1-2 Diodes................................................................................... 72 1-3 Foot Switch.............................................................................. 72 1-4 Toggle Switches.......................................................................... 73 How to Test a Toggle Switch.............................................................. 73 Platform Components.............................................................................. 74 2-1 Platform Leveling Slave Cylinder......................................................... 74 How to Remove the Platform Leveling Slave Cylinder....................................... 74 How to Bleed the Leveling Slave Cylinder................................................. 74 2-2 Platform Rotator......................................................................... 75 How to Remove the Platform Rotator....................................................... 75 How to Bleed the Platform Rotator........................................................ 76 2-3 Platform Overload System................................................................. 77 How to Calibrate the Platform Overload System (if equipped).............................. 77 Jib Boom Components.............................................................................. 79 3-1 Jib Boom................................................................................. 79 How to Remove the Jib Boom............................................................... 79 3-2 Jib Boom Bell Crank...................................................................... 80 How to Remove the Jib Boom Bell Crank.................................................... 80 3-3 Jib Boom Lift Cylinder................................................................... 80 How to Remove the Jib Boom Lift Cylinder................................................. 80 Primary Boom Components.......................................................................... 82 4-1 Cable Track.............................................................................. 82 How to Repair the Primary Boom Cable Track............................................... 82 4-2 Primary Boom............................................................................. 82 How to Shim the Primary Boom............................................................. 82 How to Remove the Primary Boom........................................................... 82 How to Disassemble the Primary Boom...................................................... 84 4-3 Primary Boom Lift Cylinder............................................................... 85 How to Remove the Primary Boom Lift Cylinder............................................. 85 4-4 Primary Boom Extension Cylinder.......................................................... 87 How to Remove the Primary Boom Extension Cylinder........................................ 87 4-5 Platform Leveling Master Cylinder........................................................ 88 How to Remove the Platform Leveling Master Cylinder...................................... 88 Secondary Boom Components........................................................................ 90 5-1 Secondary Boom........................................................................... 91 How to Disassemble the Secondary Boom.................................................... 91 5-2 Secondary Boom Lift Cylinders............................................................ 94 How to Remove the Secondary Boom Lift Cylinders.......................................... 94 Engines.......................................................................................... 96 6-1 Timing Adjustment........................................................................ 96 6-2 RPM Adjustment........................................................................... 96 6-3 Engine Drive Pulley...................................................................... 96 How to Remove the Engine Drive Pulley.................................................... 96 How to Install the Engine Drive Pulley................................................... 97 6-4 Coolant Temperature and Oil Pressure Switches............................................ 98 Generator........................................................................................ 99 7-1 Generator Pulley......................................................................... 99 How to Remove the Generator Pulley....................................................... 99 How to Install the Generator Pulley...................................................... 99 7-2 Generator Belts..........................................................................100 7-3 Generator Voltage Regulator..............................................................101 How to Adjust the Generator Voltage Regulator............................................101 How to Replace the Voltage Regulator.....................................................102 Hydraulic Pumps..................................................................................104 8-1 Auxiliary Pump...........................................................................104 How to Test the Auxiliary Pump...........................................................104 How to Remove the Auxiliary Pump.........................................................104 8-2 Function Pump............................................................................105 How to Test the Function Pump............................................................105 How to Removet the Function Pump.........................................................105 Manifolds........................................................................................107 9-1 Function Manifold Components.............................................................107 9-2 Valve Adjustments - Function Manifold....................................................109 How to Adjust the System Relief Valve....................................................109 How to Adjust the Primary Boom Down Relief Valve.........................................109 How to Adjust the Secondary Boom Down Relief Valve.......................................110 How to Adjust the Turntable Rotate Relief Valve..........................................110 9-3 Jib Boom / Platform Rotate Manifold Components...........................................111 9-4 Valve Coils..............................................................................112 How to Test a Coil.......................................................................112 Valve Coil Resistance Specification......................................................112 How to Test a Coil Diode.................................................................113 Fuel and Hydraulic Tanks.........................................................................114 10-1 Fuel Tank...............................................................................114 How to Remove the Fuel Tank..............................................................114 10-2 Hydraulic Tank..........................................................................114 How to Remove the Hydraulic Tank.........................................................114 Turntable Rotation Components....................................................................116 11-1 Rotation Hydraulic Motor................................................................116 How to Remove the Turntable Rotation Motor...............................................116 Axle Components..................................................................................117 12-1 Yoke and Hub............................................................................117 How to Remove the Yoke and Hub...........................................................117 How to Remove the Hub and Bearings.......................................................117 How to Install the Hub and Bearings......................................................118 12-2 Steer Cylinder..........................................................................118 Non-steer Axle Components........................................................................119 13-1 Drive Motor.............................................................................119 13-2 Drive Hubs..............................................................................119 Motor Controller.................................................................................121 14-1 Motor Controller........................................................................121 Fault Codes..........................................................................................122 Fault Code Charts................................................................................124 Schematics...........................................................................................128 Electrical Symbol Legend.........................................................................129 Hydraulic Symbols Legend.........................................................................130 Electrical Schematic - from serial number 4800 to 5426 (ANSI / CSA)..............................133 Electrical Schematic - from serial number 4800 to 5426 (CE)......................................137 Electrical Schematic - from serial number 5427 to 9441 (ANSI / CSA)..............................141 Electrical Schematic - from serial number 9442 to 9685 (ANSI / CSA)..............................145 Electrical Schematic - from serial number 5427 to 9441 (CE)......................................149 Electrical Schematic - from serial number 9442 to 9685 (CE / AS).................................153 Ground Control Box Switch Panel Wiring Diagram...................................................157 Ground Control Box Terminal Strip Wiring Diagram.................................................158 Ground Control Box Terminal Strip Wiring Diagram - from serial number 9442 to 9685 (ANSI/CSA)....161 Ground Control Box Terminal Strip Wiring Diagram - from serial number 9442 to 9685 (CE / AS).....162 Platform Control Box Wiring Diagram..............................................................165 Power Cable Wiring Diagram.......................................................................170 Drive Contactor Panel Wiring Diagram.............................................................173 Drive Contactor Panel Wiring Diagram - from 7223.................................................174 Manifold and Limit Switch Wiring Diagram.........................................................176 LVI / BCI Option Wiring Diagram, from serial number 4800 to 5426.................................179 LVI / BCI Option Wiring Diagram, from serial number 5427.........................................180 Engine Wiring Diagram............................................................................183 Hydraulic Schematic..............................................................................184 Back Cover...........................................................................................186
S.S 04/24
