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Genie Z-34/22N Z-34/22 DC Service Manual 36540 – PDF DOWNLOAD
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Genie Z-34/22N Z-34/22 DC Service Manual 36540 – PDF DOWNLOAD
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Description
Genie Z-34/22N Z-34/22 DC Service Manual 36540 – PDF DOWNLOAD
Language : English
Pages : 341
Downloadable : Yes
File Type : PDF
Table of Contents:
Genie Z-34/22N Z-34/22 DC Service Manual 36540 – PDF DOWNLOAD
Safety Rules......................................................................................................................................... 3 Theory of Operation.................................................................................................................................. 5 Table of Contents.................................................................................................................................... 7 Specifications....................................................................................................................................... 21 Machine Specifications........................................................................................................................... 21 Performance Specifications....................................................................................................................... 22 Hydraulic Specifications......................................................................................................................... 23 Hydraulic Hose and Fitting Torque Specifications................................................................................................. 24 SAE and Metric Fastener Torque Chart............................................................................................................. 25 Scheduled Maintenance Inspections.................................................................................................................... 27 Maintenance Tables............................................................................................................................... 28 Maintenance Inspection Report.................................................................................................................... 31 Scheduled Maintenance Procedures................................................................................................................. 33 Table A Procedures............................................................................................................................... 34 A-1 Inspect the Operator's and Safety Manuals................................................................................................ 34 A-2 Inspect the Decals and Placards.......................................................................................................... 34 A-3 Inspect for Damage and Loose or Missing Parts............................................................................................ 35 A-4 Check the Hydraulic Oil Level............................................................................................................ 35 A-5 Check for Hydraulic Leaks................................................................................................................ 36 A-6 Test the Platform and Ground Controls.................................................................................................... 37 A-7 Test the Auxiliary Power Operation....................................................................................................... 39 A-8 Test the Tilt Sensor..................................................................................................................... 40 A-9 Test the Limit Switches.................................................................................................................. 40 A-10 Test the Lift/Drive Select Switch (if equipped)......................................................................................... 43 A-11 Perform 30 Day/50 hour Service.......................................................................................................... 43 Table B Procedures............................................................................................................................... 44 B-1 Check the Batteries...................................................................................................................... 44 B-2 Inspect the Electrical Wiring............................................................................................................ 45 B-3 Inspect the Tires and Wheels (including lug nut torque).................................................................................. 46 B-4 Confirm the Proper Brake Configuration................................................................................................... 46 B-5 Check the Oil Level in the Drive Hubs.................................................................................................... 47 B-6 Test the Key Switch...................................................................................................................... 48 B-7 Test the Emergency Stop Buttons.......................................................................................................... 48 B-8 Test the Ground Control Override......................................................................................................... 49 B-9 Test the Platform Self-leveling.......................................................................................................... 49 B-10 Test the Horn........................................................................................................................... 50 B-11 Test the Foot Switch.................................................................................................................... 50 B-12 Test the Drive Enable System............................................................................................................ 51 B-13 Test the Drive Brakes................................................................................................................... 52 B-14 Test the Drive Speed - Stowed Position.................................................................................................. 53 B-15 Test the Drive Speed - Raised or Extended Position...................................................................................... 54 B-16 Test the Alarm Package (if equipped).................................................................................................... 55 B-17 Test the Turntable Rotation Stop........................................................................................................ 56 B-18 Check the Electrical Contactors......................................................................................................... 57 B-19 Perform Hydraulic Oil Analysis.......................................................................................................... 57 B-20 Replace the Hydraulic Tank Return Filter................................................................................................ 58 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....................................................................................................... 62 C-4 Grease the Turntable Rotation Bearing and Worm Drive Gear................................................................................ 63 C-5 Replace the Drive Hub Oil................................................................................................................ 63 C-6 Bleed the Platform Rotator............................................................................................................... 64 Table D Procedures............................................................................................................................... 65 D-1 Test or Replace the Hydraulic Oil........................................................................................................ 65 D-2 Grease the Steer Axle Wheel Bearings..................................................................................................... 67 Troubleshooting Flow Charts.......................................................................................................................... 69 Fault Code Chart (Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226)........................................................ 71 Chart 1 All Functions Will Not Operate........................................................................................................... 75 Chart 2 Lift Pump Motor Will Not Operate......................................................................................................... 78 Chart 3 Auxiliary Pump Motor Will Not Operate.................................................................................................... 85 Chart 4 All Functions Inoperative, Poer Unit Starts and Runs..................................................................................... 88 Chart 5 All Lift and Steer Functions Inoperative, Drive Function Operational..................................................................... 89 Chart 6 Ground Controls Inoperative, Platform Controls Operate Normally.......................................................................... 93 Chart 7 Platform Controls Inoperative, Ground Controls Operate Normally (before Z34/22-1734 and Z34/22N-2227).................................... 95 Chart 8 Platfrom Controls Inoperative, Ground Controls Operate Normally (after Z34/22-1733 and Z34/22N-2226)..................................... 99 Chart 9 Primary Boom Up Function Inoperative.....................................................................................................102 Chart 10 Primary Boom Down Function Inoperative..................................................................................................106 Chart 11 Secondary Boom Up Function Inoperative..................................................................................................110 Chart 12 Secondary Boom Down Function Inoperative................................................................................................114 Chart 13 Primary Boom Extend Function Inoperative................................................................................................118 Chart 14 Primary Boom Retract Function Inoperative...............................................................................................123 Chart 15 Turntable Rotate Left Function Inoperative..............................................................................................128 Chart 16 Turntable Rotate Right Function Inoperative.............................................................................................133 Chart 17 All Platform Level Functions Inoperative................................................................................................137 Chart 18 Platform Level Up Function Inoperative..................................................................................................139 Chart 19 Platform Level Down Function Inoperative................................................................................................144 Chart 20 Platform Rotate Left Function Inoperative...............................................................................................148 Chart 21 Platform Rotate Right Function Inoperative..............................................................................................152 Chart 22 Jib Boom Up Function Inoperative........................................................................................................156 Chart 23 Jib Boom Down Function Inoperative......................................................................................................159 Chart 24 Steer Left Function Inoperative (before Z34/22-1734 and Z34/22N-2227)...................................................................162 Chart 25 Steer Left Function Inoperative (after Z34/22-1733 and Z34/22N-2226)....................................................................163 Chart 26 Steer Right Function Inoperative (before Z34/22-1734 and Z34/22N-2227)..................................................................165 Chart 27 Steer Right Function Inoperative (after Z34/22-1733 and Z34/22N-2226)...................................................................166 Chart 28 All Drive Functions Inoperative, All other Functions Operate Normally (before Z34/22-1734 and Z34/22N-2227).............................168 Chart 28A Brake Function Inoperative (before Z34/22-1734 and Z34/22N-2227).......................................................................174 Chart 29 All Drive Functions Inoperative, All Other Functions Operate Normally (after Z34/22-1733 and Z34/22N-2226)..............................178 Chart 29A Motor Controller fault Code 21: Throttle Fault (after Z34/22-1733 and Z34/22N-2226)....................................................180 Chart 29B Motor Controller Fault Code 32: Main Contactor Welded (after Z34/22-1733 and Z34/22N-2226).............................................181 Chart 29C Motor Controller Fault Code 34: Missing Main Contactor Did Not Close (after Z34/22-1733 and Z34/22N-2226)..............................182 Chart 30 Brake Release Function Inoperative (after Z34/22-1733 and Z34/22N-2226).................................................................185 Chart 31 Drive Forward Function Inoperative (before Z34/22-1734 and Z34/22N-2227)................................................................188 Chart 32 Drive Reverse Function Inoperative (before Z34/22-1734 and Z34/22N-2227)................................................................189 Chart 33 Machine Will Not Drive At Full Speed (before Z34/22-1734 and Z34/22N-2227)..............................................................190 Chart 34 Machine Will Not Drive At Full Speed (after Z34/22-1733 and Z34/22N-2226)...............................................................191 Chart 35 Machine Drives At Full Speed With Platform Raised Or Extended (before Z34/22-1734 and Z34/22N-2227).....................................193 Chart 36 Machine Drives At Full Speed With Platform Raised Or Extended (after Z34/22-1733 and Z34/22N-2226)......................................194 Chart 37 Drive enable System Is Malfunctioning (before Z34/22-1734 and Z34/22N-2227).............................................................195 Chart 38 Drive Enable System Is Malfunctioning (after Z34/22-1733 and Z34/22N-2226)..............................................................197 Chart 39 Remote Brake Release Inoperative (before Z34/22-3578 and Z34/22N-4261)..................................................................198 Schematics...........................................................................................................................................199 Electrical Components............................................................................................................................200 Load Sensor Option Diagram (Z-34/22 before serial number 1734 and Z-34/22N before serial number 2227)............................................202 Load Sensor Option Diagram (Z-34/22 from serial number 1734 to 2060 and Z-34/22N from serial number 2227 to 2870)................................203 Load Sensor Option Diagram (Z-34/22 from serial number 2061 to 3577 and Z-34/22N from serial number 2871 to 4260)................................204 Power Cable Diagram (Z-34/22 before serial number 3578 and Z-34/22N before serial number 4261)...................................................205 Power Cable Diagram (Z-34/22 after serial number 3577 and Z-34/22N after serial number 4260).....................................................206 Abbreviations Legend.............................................................................................................................207 Electrical Symbols Legend........................................................................................................................208 Hydraulic Symbols Legend.........................................................................................................................209 Electrical Schematic (Z-34/22 before serial number 153 and Z-34/22N before serial number 304)....................................................212 Electrical Schematic (Z-34/22 from serial number 153 to 1733 and Z-34/22N from serial number 304 to 2226)........................................216 Electrical Schematic (Z-34/22 from serial number 1734 to 1834 and Z-34/22N from serial number 2227 to 2447)......................................220 Electrical Schematic (Z-34/22 from serial number 1835 to 2060 and Z-34/22N from serial number 2448 to 2870)......................................224 Electrical Schematic (Z-34/22 from serial number 2061 to 3577 and Z-34/22N from serial number 2871 to 4260)......................................228 Electrical Schematic (Z-34/22 from serial number 3578 to 4799 and Z-34/22N after serial number 4261 to 5619......................................232 Electrical Schematic (Z-34/22 after serial number 4799 and Z-34/22N after serial number 5619.....................................................236 Electrical Schematic - CE Models (Z-34/22 after serial number 4799 and Z-34/22N after serial number 5619)........................................240 Ground Control Panel Legend (Z-34/22 before serial number 153 and Z-34/22N before serial number 304).............................................244 Ground Control Panel Wiring Diagram (Z-34/22 from serial number 153 to 1733 and Z-34/22N from serial number 304 to 2226).........................245 Ground Control Panel Wiring Diagram (Z-34/22 from serial number 1734 to 1999 and Z-34/22N from serial number 2227 to 2750).......................248 Ground Control Panel Wiring Diagram (Z-34/22 from serial number 2000 to 3577 and Z-34/22N from serial number 2751 to 4260).......................249 Ground Control Panel Wiring Diagram (Z-34/22 from serial number 3578 to 4799 and Z-34/22N from serial number 4261 to 5619).......................252 Ground Control Panel Wiring Diagram (Z-34/22 after serial number 4799 and Z-34/22N after serial number 5619).....................................253 Ground Control Terminal Strip Wiring Diagram (Z-34/22 after serial number 4799 and Z-34/22N after serial number 5619)............................255 Platform Control Box Wiring Diagram (Z-34/22 before serial number 1734 and Z-34/22N before serial number 2227)...................................258 Platform Control Box Wiring Diagram (Z-34/22 from serial number 1734 to 1834 and Z-34/22N from serial number 2227 to 2448).......................259 Platform Control Box Wiring Diagram (Z-34/22 from serial number 1835 to 2060 and Z-34/22N from serial number 2449 to 2870).......................262 Platform Control Box Wiring Diagram (Z-34/22 from serial number 2061 to 3577 and Z-34/22N from serial number 2871 to 4260).......................263 Platform Control Box Wiring Diagram (Z-34/22 after serial number 3577 and Z-34/22N after serial number 4260).....................................265 Hydraulic Schematic (Z-34/22 before serial number 674 and Z-34/22N before serial number 935).....................................................268 Hydraulic Schematic (Z-34/22 from serial number 674 to 1733 and Z-34/22N from serial number 935 to 2226).........................................269 Hydraulic Schematic (Z-34/22 from serial number 1734 to 2005 and Z-34/22N from serial number 2227 to 2771).......................................272 Hydraulic Schematic (Z-34/22 from serial number 2006 to 2900 and Z-34/22N from serial number 2772 to 3532).......................................273 Hydraulic Schematic (Z-34/22 after serial number 2900 and Z-34/22N after serial number 3532).....................................................275 Repair Procedures....................................................................................................................................277 Platform Controls................................................................................................................................278 1-1 Controllers..............................................................................................................................278 1-2 Foot Switch..............................................................................................................................285 1-3 Toggle Switches..........................................................................................................................286 Platform Components..............................................................................................................................287 2-1 Platfrom.................................................................................................................................287 2-2 Platform Leveling Slave Cylinder.........................................................................................................287 2-3 Platform Rotator.........................................................................................................................289 Jib Boom Components..............................................................................................................................292 3-1 Jib Boom.................................................................................................................................292 3-2 Jib Boom Bell Crank......................................................................................................................293 3-3 Jib Boom Lift Cylinder...................................................................................................................294 Primary Boom Components..........................................................................................................................295 4-1 Plastic Cable Track......................................................................................................................295 4-2 Primary boom.............................................................................................................................295 4-3 Primary Boom Lift Cylinder...............................................................................................................299 4-4 Extension Cylinder.......................................................................................................................301 4-5 Platform Leveling Master Cylinder........................................................................................................302 Secondary Boom Components........................................................................................................................304 5-1 Secondary Boom...........................................................................................................................305 5-2 Secondary Boom Lift Cylinder.............................................................................................................309 Ground Controls..................................................................................................................................310 6-1 Control Relays...........................................................................................................................310 6-2 Toggle Switches..........................................................................................................................312 6-3 Wago® Components.........................................................................................................................312 Hydraulic Pumps..................................................................................................................................313 7-1 Auxiliary Pump...........................................................................................................................313 7-2 Main Function Pump.......................................................................................................................314 Manifolds........................................................................................................................................316 8-1 Function Manifold Components (Z-34/22 before serial number 674 and Z-34/22N before serial number 935)....................................316 8-2 Function manifold Components (Z-34/22 from serial number 674 to 1733 and Z-34/22N from serial number 935 to 2226)........................318 8-3 Function Manifold Components (Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226)....................................320 8-4 Valve Adjustments - Function Manifold....................................................................................................322 8-5 Jib Boom / Platform Rotate Manifold Components (Z-34/22 before serial number 1734 and Z-34/22N before serial number 2227)................327 8-6 Jib Boom / Platform Rotate Manifold Components (Z-34/22 from serial number 1734 to 2005 and Z-34/22N from serial number 2227 to 2771)....328 8-7 Jib Boom / Platform Rotate Manifold Components (Z-34/22 after serial number 2005 and Z-34/22N after serial number 2771)..................329 8-8 Steer / Brake Manifold Components (Z-34/22 before serial number 781 and Z-34/22N before serial number 1030)..............................330 8-9 Steer / Brake Manifold Components (Z-34/22 from serial number 781 to 1733 and Z-34/22N from serial number 1030 to 2226)..................331 Hydraulic Tank...................................................................................................................................332 9-1 Hydraulic Tank...........................................................................................................................332 Turntable Rotation Components....................................................................................................................334 10-1 Turntable Rotation Hydraulic Motor......................................................................................................334 Steer Axle Components............................................................................................................................335 11-1 Yoke and Hub............................................................................................................................335 11-2 Steer Cylinder..........................................................................................................................337 11-3 Tie Rod.................................................................................................................................337 Non-steer Axle Components........................................................................................................................338 12-1 Drive Motor.............................................................................................................................338 12-2 Drive Hub...............................................................................................................................338 Motor Controller.................................................................................................................................340 13-1 Motor Controller (Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226)...............................................340
S.S 05/24
