Genie Z-34/22 IC Service Manual 43037 – PDF DOWNLOAD

Description

Genie Z-34/22 IC Service Manual 43037 – PDF DOWNLOAD

Language : English
Pages : 275
Downloadable : Yes
File Type : PDF

Table of Contents:

Genie Z-34/22 IC Service Manual 43037 – PDF DOWNLOAD

Safety Rules..............................................................................................  3
Table of Contents.........................................................................................  5
Specifications............................................................................................ 15
	Machine Specifications................................................................................ 15
	Performance Specifications............................................................................ 16
	Hydraulic Specifications.............................................................................. 16
	Bolt Torque Specifications............................................................................ 18
	Kubota WG-750 Engine.................................................................................. 19
	Kubota D-905 Engine................................................................................... 21
Scheduled Maintenance Inspections......................................................................... 23
	Maintenance Tables.................................................................................... 24
	Maintenance Inspection Report......................................................................... 29
Scheduled Maintenance Procedures.......................................................................... 31
	Table A Procedures.................................................................................... 32
		A-1 Inspect the Operator's and Safety Manuals..................................................... 32
		A-2 Inspect the Decals and Placards............................................................... 32
		A-3 Inspect for Damage, Loose or Missing Parts.................................................... 33
		A-4 Check the Engine Oil Level.................................................................... 33
		A-5 Check the Engine Coolant Level................................................................ 34
		A-6 Check for Fuel Leaks.......................................................................... 34
		A-7 Check the Hydraulic Oil Level................................................................. 35
		A-8 Check for Hydraulic Leaks..................................................................... 35
		A-9 Check the Tire Pressure....................................................................... 36
		A-10 Test the Platform and Ground Controls........................................................ 36
		A-11 Test the Auxiliary Power Operation........................................................... 37
		A-12 Test the Tilt Sensor......................................................................... 38
		A-13 Test the Limit Switches...................................................................... 38
		A-14 Perform 30 Day Service....................................................................... 40
		A-15 Clean the Air Filter Element................................................................. 40
		A-16 Drain the Fuel Filter / Water Separator - Kubota Diesel Models............................... 41
		A-17 Check the Engine Belt........................................................................ 42
		A-18 Replace the Engine Oil and Filter............................................................ 42
	Table B Procedures.................................................................................... 44
		B-1 Check the Radiator............................................................................ 44
		B-2 Check the Engine Choke - Kubota Gasoline/LPG Models........................................... 44
		B-3 Check the Exhaust System...................................................................... 45
		B-4 Check the Battery............................................................................. 45
		B-5 Inspect the Electrical Wiring................................................................. 46
		B-6 Inspect the Tires and Wheels (including lug nut torque)....................................... 46
		B-7 Confirm Proper Brake Configuration............................................................ 47
		B-8 Check the Oil Level in the Torque Hubs........................................................ 47
		B-9 Check the Glow Plugs - Kubota Diesel Models................................................... 48
		B-10 Check and Adjust the Engine RPM.............................................................. 48
		B-11 Test the Key Switch.......................................................................... 50
		B-12 Test the Emergency Stop Buttons.............................................................. 50
		B-13 Test the Ground Control Override............................................................. 51
		B-14 Test the Platform Self-leveling.............................................................. 51
		B-15 Test the Service Horn........................................................................ 52
		B-16 Test the Foot Switch......................................................................... 52
		B-17 Test the Engine Idle Select.................................................................. 53
		B-18 Test the Fuel Select Operation - Kubota Gasoline/LPG Models.................................. 54
		B-19 Test the Drive Enable System................................................................. 54
		B-20 Test the Drive Brakes........................................................................ 55
		B-21 Test the Drive Speed - Stowed Position....................................................... 56
		B-22 Test the Drive Speed - Raised or Extended Position........................................... 56
		B-23 Test the Alarm Package - Optional Equipment.................................................. 57
		B-24 Perform Hydraulic Oil Analysis............................................................... 58
		B-25 Replace the Diesel Fuel Filter / Water Separator Element - Kubota Diesel Models.............. 59
	Table C Procedures.................................................................................... 60
		C-1 Check the Primary Boom Wear Pads.............................................................. 60
		C-2 Check the Turntable Rotation Bearing Bolts.................................................... 60
		C-3 Check the Free-wheel Configuration............................................................ 61
		C-4 Grease the Turntable Rotation Bearing and Worm Drive Gear..................................... 62
		C-5 Replace the Torque Hub Oil.................................................................... 63
		C-6 Replace the Hydraulic Filters................................................................. 63
		C-7 Replace the Gasoline Fuel Filter - Kubota Gasoline/LPG Models................................. 64
		C-8 Clean or Replace the Distributor Cap and Rotor - Kubota Gasoline/LPG Models................... 65
		C-9 Replace the Spark Plugs - Kubota Gasoline/LPG Models.......................................... 66
		C-10 Check and Adjust the Air/LPG Mixture - Kubota Gasoline/LPG Models............................ 67
		C-11 Replace the Engine Air Filter................................................................ 68
		C-12 Check and Adjust the Ignition Timing - Kubota Gasoline/LPG Models............................ 69
		C-13 Check the Engine Valve Clearances - Kubota Gasoline/LPG Models............................... 69
		C-14 Bleed the Platform Rotator................................................................... 69
	Table D Procedures.................................................................................... 70
		D-1 Test or Replace the Hydraulic Oil............................................................. 70
		D-2 Change or Recondition the Engine Coolant...................................................... 71
		D-3 Change the Fuel Lines......................................................................... 72
Troubleshooting Flow Charts............................................................................... 75
	Chart 1 Engine Will Not Crank Over - Kubota Gas/LPG Models............................................ 77
	Chart 2 Engine Cranks But Will Not Start - Kubota Gas/LPG Models...................................... 79
	Chart 2A Engine Cranks But Will Not Start OR Runs While Cranking Then Dies - Kubota Gas/LPG Models.... 81
	Chart 2B Engine Runs While Cranking Then Dies - Kubota Gas/LPG Models................................. 84
	Chart 3 Engine Cranks Over But Will Not Start - Kubota Diesel Models.................................. 85
	Chart 4 Engine Will Not Start On LPG, But Will Start On Gasoline - Kubota Gasoline/LPG Models......... 88
	Chart 5 Engine Choke Inoperative - Kubota Gasoline/LPG Models......................................... 90
	Chart 6 Engine Glow Plugs Inoperative - Kubota Diesel Models.......................................... 93
	Chart 7 Engine Will Not Start On Gasoline, But Will Start On LPG - Kubota Gasolin/LPG Models.......... 95
	Chart 8 Engine High Idle Inoperative - Kubota Gasoline/LPG Models..................................... 97
	Chart 9 Engine Low Idle Inoperative - Kubota Gasoline/LPG Models...................................... 99
	Chart 10 Engine High Idle Inoperative - Kubota Diesel Models..........................................100
	Chart 11 Engine Low Idle Inoperative - Kubota Diesel Models...........................................102
	Chart 12 All Functions Inoperative, Engine Starts and Runs............................................103
	Chart 13 All Lift and Steer Functions Inoperative, Drive Functions Operational........................104
	Chart 14 Ground Controls Inoperative, Platform Controls Operate Normally..............................105
	Chart 15 Platform Controls Inoperative, Ground Controls Operate Normally..............................106
	Chart 16 Primary Boom Up Function Inoperative.........................................................107
	Chart 17 Primary Boom Down Function Inoperative.......................................................110
	Chart 18 Secondary Boom Up Function Inoperative.......................................................113
	Chart 19 Secondary Boom Down Function Inoperative.....................................................116
	Chart 20 Primary Boom Extend Function Inoperative.....................................................119
	Chart 21 Primary Boom Retract Function Inoperative....................................................122
	Chart 22 Turntable Rotate Left Function Inoperative...................................................125
	Chart 23 Turntable Rotate Right Function Inoperative..................................................128
	Chart 24 All Platform Leveling Functions Inoperative..................................................131
	Chart 25 Platform Level Up Function Inoperative.......................................................132
	Chart 26 Platform Level Down Function Inoperative.....................................................135
	Chart 27 Platform Rotate Left Function Inoperative....................................................138
	Chart 28 Platform Rotate Right Function Inoperative...................................................141
	Chart 29 Jib Boom Up Function Inoperative.............................................................144
	Chart 30 Jib Boom Down Function Inoperative...........................................................147
	Chart 31 Steer Left Function Inoperative..............................................................150
	Chart 32 Steer Right Function Inoperative.............................................................151
	Chart 33 All Drive Functions Inoperative, All Other Functions Operate Normally........................152
	Chart 34 Drive Forward or Reverse Function Inoperative................................................155
	Chart 35 Traction Function Inoperative................................................................156
	Chart 36 Machine Will Not Drive At Full Speed.........................................................157
	Chart 37 Machine Drives At Full Speed With Platform Raised Or Extended................................158
	Chart 38 Drive Enable System Is Malfunctioning........................................................159
	Chart 39 Auxiliary Functions Inoperative..............................................................160
Schematics................................................................................................161
	Electrical Symbols Legend.............................................................................162
	Hydraulic Symbols Legend..............................................................................163
	Electrical Schematic, Diesel Models (before serial number 869)........................................166
	Electrical Schematic, Diesel Models (from serial number 869 to 1186)..................................170
	Electrical Schematic, Gasoline/LPG Models (before serial number 869)..................................174
	Electrical Schematic, Gasoline/LPG Models (869 to 1186)...............................................178
	Ground Control Box Wiring Diagram, Diesel Models (before serial number 869)...........................182
	Ground Control Box Wiring Diagram, Diesel Models (from serial number 869 to 1186).....................183
	Ground Control Box Wiring Diagram, Gasoline/LPG Models (before serial number 869).....................186
	Ground Control Box Wiring Diagram, Gasoline/LPG Models (from serial number 869 to 1186)...............187
	Platform Control Box Wiring Diagram, Diesel Models....................................................190
	Platfrom Control Box Wiring Diagram, Gasoline/LPG Models..............................................191
	Hydraulic Schematic, 2WD Models (before serial number 674)............................................194
	Hydraulic Schematic, 2WD Models (from serial number 674 to 1029)......................................198
	Hydraulic Schematic, 2WD Models (from serial number 1030 to 1186).....................................202
	Hydraulic Schematic, 4WD Models (before serial number 674)............................................206
	Hydraulic Schematic, 4WD Models (from serial number 674 to 1029)......................................210
	Hydraulic Schematic, 4WD Models (from serial number 1030 to 1186).....................................214
Repair Procedures.........................................................................................217
	Platform Controls.....................................................................................218
		1-1 Horsepower Limiter Board......................................................................218
		1-2 Diodes........................................................................................220
		1-3 Foot Switch...................................................................................221
		1-4 Toggle Switches...............................................................................222
	Platform Components...................................................................................223
		2-1 Platform......................................................................................223
		2-2 Platform Leveling Slave Cylinder..............................................................223
		2-3 Platform Rotator..............................................................................224
	Jib Boom Components...................................................................................226
		3-1 Jib Boom......................................................................................226
		3-2 Jib Boom Lift Cylinder........................................................................227
		3-3 Jib Boom / Platform Rotate Manifold Components (before serial number 1030)....................228
		3-4 Jib Boom / Platform Rotate Manifold Components (after serial number 1029).....................229
	Primary Boom Components...............................................................................230
		4-1 Plastic Cable Track...........................................................................230
		4-2 Primary Boom..................................................................................230
		4-3 Primary Boom Lift Cylinder....................................................................233
		4-4 Extension Cylinder............................................................................234
		4-5 Platform Leveling Master Cylinder.............................................................235
	Secondary Boom Components.............................................................................238
		5-1 Secondary Boom................................................................................239
		5-2 Secondary Boom Lift Cylinder..................................................................242
	Kubota D-905 Engine...................................................................................243
		6-1 Timing Adjustment.............................................................................243
		6-2 Glow Plugs....................................................................................243
		6-3 Engine RPM....................................................................................243
		6-4 Flex Plate....................................................................................243
		6-5 Water Temperature and Oil Pressure Gauges.....................................................244
	Kubota WG-750 Engine..................................................................................245
		7-1 Choke Adjustments.............................................................................245
		7-2 Timing Adjustments............................................................................245
		7-3 Carburetor Adjustment.........................................................................245
		7-4 RPM Adjustment................................................................................245
		7-5 Flex Plate....................................................................................245
		7-6 Water Temperature and Oil Pressure Gauges.....................................................246
		7-7 Vacuum Switch.................................................................................247
	Ground Controls.......................................................................................248
		8-1 Control Relays................................................................................248
		8-2 Toggle Switches...............................................................................249
		8-3 Wago Components...............................................................................249
	Hydraulic Pumps.......................................................................................250
		9-1 Auxiliary Pump................................................................................250
		9-2 Lift/Steer Pump...............................................................................250
		9-3 Drive Hydraulic Pump..........................................................................251
	Function Manifold.....................................................................................254
		10-1 Function Manifold Components.................................................................254
		10-2 Valve Adjustments - Function Manifold........................................................258
	Fuel and Hydraulic Tanks..............................................................................261
		11-1 Fuel Tank....................................................................................261
		11-2 Hydraulic Tank...............................................................................261
	Turntable Rotation Components.........................................................................262
		12-1 Rotation Hydraulic Motor.....................................................................262
	2WD Steering Axle Components..........................................................................263
		13-1 Yoke and Hub.................................................................................263
		13-2 Steer Cylinder...............................................................................264
	4WD Steering Axle Components..........................................................................265
		14-1 Yoke and Hub.................................................................................265
		14-2 Steer Cylinder...............................................................................266
		14-3 Tie Rod......................................................................................266
	Brake and Two Speed Manifold..........................................................................267
		15-1 Brake and Two Speed Manifold Components......................................................267
	Non-steering Axle Components..........................................................................268
		16-1 Drive Motor..................................................................................268
		16-2 Torque Hub...................................................................................268
	2WD Drive Manifold....................................................................................270
		17-1 2WD Drive Manifold Components................................................................270
		17-2 Valve Adjustments............................................................................271
	4WD Drive Manifold....................................................................................272
		18-1 4WD Drive Manifold Components................................................................272
		18-2 Valve Adjustments............................................................................274

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