Genie Z-40/23N Z-40/23N RJ Service Manual 119817 – PDF DOWNLOAD

Description

Genie Z-40/23N Z-40/23N RJ Service Manual 119817 – PDF DOWNLOAD

Language : English
Pages : 166
Downloadable : Yes
File Type : PDF

Table of Contents:

Genie Z-40/23N Z-40/23N RJ Service Manual 119817 – PDF DOWNLOAD

Front Cover................................................................  1
Introduction Introduction..................................................  2
	Important Information..................................................  2
	Find a Manual for this Model...........................................  2
	Revision History.......................................................  3
	Serial Number Legend...................................................  5
General Safety Rules
......................................................  6
Table of Contents..........................................................  8
Specifications............................................................. 14
	Machine Specifications................................................. 14
	Performance Specifications............................................. 15
	Hydraulic Specification................................................ 16
	Hydraulic Component Specifications..................................... 18
	Manifold Component Specifications...................................... 18
	Machine Torque Specifications.......................................... 19
	Hydraulic Hose and Fitting Torque Specifications....................... 20
	Torque Procedure....................................................... 21
	SAE and Metric Fasteners Torque Charts................................. 23
Scheduled Maintenance Procedures........................................... 24
	Introduction........................................................... 24
	Pre-Delivery Preparation Report........................................ 27
	Maintenance Inspection Report.......................................... 29
	Checklist A Procedures................................................. 30
		A-1 Inspect the Manuals and Decals................................. 30
		A-2 Perform Pre-operation Inspection............................... 31
		A-3 Perform Function Tests......................................... 31
		A-4 Perform 30 Day Service......................................... 32
		A-5 Grease the Turntable Rotation Bearing and Worm Drive Gear...... 32
	Checklist B Procedures................................................. 33
		B-1 Inspect the Battery............................................ 33
		B-2 Inspect the Electrical Wiring.................................. 34
		B-3 Inspect the Tires, Wheels and Lug Nut Torque................... 36
		B-4 Confirm the Proper Brake Configuration......................... 36
		B-5 Check the Oil Level in the Drive Hubs.......................... 37
		B-6 Test the Ground Control Override............................... 38
		B-7 Test the Platform Self-leveling................................ 38
		B-8 Test the Drive Brakes.......................................... 39
		B-9 Test the Drive Speed - Stowed Position......................... 39
		B-10 Test the Drive Speed - Raised or Extended Position............ 40
		B-11 Test the Alarm Package (if equipped).......................... 41
		B-12 Inspect the Electrical Contactor.............................. 41
		B-13 Perform Hydraulic Oil Analysis................................ 42
		B-14 Test the Emergency Power System............................... 42
	Checklist C Procedures................................................. 44
		C-1 Grease the Platform Overload Mechanism (if equipped)........... 44
		C-2 Test the Platform Overload System (if equipped)................ 44
	Checklist D Procedures................................................. 47
		D-1 Check the Boom Wear Pads....................................... 47
		D-2 Check the Turntable Rotation Bearing Bolts..................... 47
		D-3 Check the Axle Mounting Bolts.................................. 49
		D-4 Check the Platform Rotation Mounting Bolts..................... 49
		D-5 Check the Free-wheel Configuration............................. 50
		D-6 Replace the Drive Hub Oil...................................... 51
		D-7 Replace the High Pressure Hydraulic Filter Element............. 51
		D-8 Inspect for Turntable Bearing Wear............................. 52
	Checklist E Procedures................................................. 54
		E-1 Test or Replace the Hydraulic Oil.............................. 54
		E-2 Grease the Steer Axle Wheel Bearings........................... 56
Repair Procedures.......................................................... 58
	Introduction........................................................... 58
	Platform Controls...................................................... 60
		1-1 Joysticks...................................................... 60
			How to Adjust the Joystick Threshold Setting................... 61
			How to Adjust the Maximum Speed Setting........................ 62
			How to Adjust the Function Ramp Up Time Setting................ 64
			How to Adjust the Function Ramp Down Time Setting.............. 66
			How to Adjust the Max Speed Drive Settings..................... 67
	Platform Components.................................................... 69
		2-1 Platform Leveling Slave Cylinder............................... 69
		2-2 Platform Rotator............................................... 70
		2-3 Platform Overload System....................................... 71
		2-4 Platform Recovery Overload..................................... 73
	Jib Boom Components.................................................... 74
		3-1 Jib Boom....................................................... 74
		3-2 Jib Boom Bell Crank (models without rotating jib boom)......... 75
		3-3 Jib Boom Rotator (models with rotating jib boom)............... 76
			How to Bleed the Jib Boom Rotator.............................. 77
		3-4 Jib Boom Lift Cylinder......................................... 78
	Primary Boom Components................................................ 79
		4-1 Cable Track.................................................... 79
			How to Remove the Cable Track.................................. 79
			How to Repair the Primary Boom Cable Track..................... 81
		4-2 Primary Boom................................................... 81
			How to Remove the Primary Boom................................. 82
			How to Disassemble the Primary Boom............................ 84
		4-3 Primary Boom Lift Cylinder..................................... 85
		4-4 Primary Boom Extension Cylinder................................ 87
		4-5 Platform Leveling Master Cylinder.............................. 88
	Secondary Boom Components.............................................. 90
		5-1 Secondary Boom................................................. 91
		5-2 Secondary Boom Lift Cylinders.................................. 95
	Hydraulic Pump......................................................... 97
		6-1 Auxiliary and Function Pump.................................... 97
		6-2 How to Remove the Function Pump................................ 98
	Manifolds..............................................................101
		7-1 Function Manifold Components...................................101
		7-2 Valve Adjustments - Function Manifold..........................103
		7-3 Jib Boom and Platform / Jib Boom Rotate Manifold Components....107
		7-4 Jib Boom and Platform / Jib Rotate Manifold Components.........108
		7-5 Valve Coils....................................................109
	Turntable Rotation Components..........................................110
		8-1 Turntable Rotation Hydraulic Motor.............................110
	Steer Axle Components..................................................112
		9-1 Hub and Bearings...............................................112
		How to Calibrate the Steer Angle Sensor............................113
	Non-steer Axle Components..............................................115
		10-1 Drive Motors..................................................115
		10-2 Drive Brake...................................................116
	Motor Controllers......................................................117
		11-1 Motor Controllers.............................................117
Fault Codes................................................................118
	Introduction...........................................................118
	Control System Fault Codes.............................................119
		How to Retrieve Control System Fault Codes - Platform Controls.....119
		How to Retrieve Control System Fault Codes - Ground Controls.......120
		Control System Fault Codes.........................................121
	Motor Controller Fault Codes...........................................129
		Motor Controller Fault Codes.......................................129
		Drive Motor Thermal Sensor.........................................132
Schematics.................................................................134
	Introduction...........................................................134
	Wire Circuit Legend....................................................135
	Wiring Coloring and Legend.............................................139
	Power Cable Diagram....................................................144
	Motor Contoller Pin Legend.............................................145
	Ground Control Box Pin Legend..........................................146
	Platform Control Box Pin Legend........................................147
	Turntable and Platform Controller Pin Legend...........................148
	Electrical Symbol Legend...............................................149
	Hydraulic Symbols Legend...............................................150
	Electrical Schematics..................................................153
		Electrical Schematic - Chassis.....................................153
		Electrical Schematic - Ground Controls.............................154
		Electrical Schematic - Platform Controls...........................157
		Ground Control Box Wiring Diagram..................................158
		Platform Control Box Wiring Diagram................................161
		Platform Control Box Wiring Diagram - Options......................162
	Hydraulic Schematics...................................................165
		Hydraulic Schematic................................................165
Back Cover.................................................................166

S.S 04/24