Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
Genie Z-45/25 Z-45/25J Bi-Energy Power Service Manual 106488 – PDF DOWNLOAD
$29.95
Genie Z-45/25 Z-45/25J Bi-Energy Power Service Manual 106488 – PDF DOWNLOAD
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
Genie Z-45/25 Z-45/25J Bi-Energy Power Service Manual 106488 – PDF DOWNLOAD
Language : English
Pages : 372
Downloadable : Yes
File Type : PDF
Table of Contents:
Genie Z-45/25 Z-45/25J Bi-Energy Power Service Manual 106488 – PDF DOWNLOAD
Safety Rules........................................................................................................................... 5 Table of Contents...................................................................................................................... 7 Specifications......................................................................................................................... 19 Machine Specifications............................................................................................................. 19 Performance Specifications......................................................................................................... 20 Hydraulic Specifications........................................................................................................... 21 Manifold Component Specifications.................................................................................................. 22 Machine Torque Specifications...................................................................................................... 22 Kubota Z482-E Engine............................................................................................................... 23 Generator.......................................................................................................................... 24 Generator Torque Specifications.................................................................................................... 24 Hydraulic Hose and Fitting Torque Specifications................................................................................... 25 SAE and Metric Fastener Torque Chart............................................................................................... 26 Scheduled Maintenance Procedures....................................................................................................... 27 Pre-delivery Preparation........................................................................................................... 29 Maintenance Inspection Report...................................................................................................... 31 Checklist A Procedures............................................................................................................. 33 A-1 Perform Pre-operation Inspection........................................................................................... 33 A-2 Perform Function Tests..................................................................................................... 33 A-3 Check the Generator Belts and Pulleys...................................................................................... 34 A-4 Perform 30 Day Service..................................................................................................... 35 A-5 Perform Engine Maintenance................................................................................................. 36 A-6 Perform Engine Maintenance................................................................................................. 36 A-7 Grease the Turntable Rotation Bearing and Rotate Gear...................................................................... 37 A-8 Perform Engine Maintenance................................................................................................. 37 A-9 Perform Engine Maintenance................................................................................................. 38 A-10 Perform Engine Maintenance................................................................................................ 38 Checklist B Procedures............................................................................................................. 39 B-1 Check the Radiator......................................................................................................... 39 B-2 Check the Exhaust System................................................................................................... 39 B-3 Check the Batteries........................................................................................................ 40 B-4 Inspect the Electrical Wiring.............................................................................................. 41 B-5 Check the Lug Nut Torque (including the tires and wheels).................................................................. 42 B-6 Confirm the Proper Brake Configuration..................................................................................... 42 B-7 Check the Oil Level in the Drive Hubs...................................................................................... 43 B-8 Check and Adjust the Engine RPM............................................................................................ 44 B-9 Test the Ground Control Override........................................................................................... 45 B-10 Test the Platform Self-leveling........................................................................................... 46 B-11 Test the Engine Idle Select............................................................................................... 46 B-12 Test the Drive Brakes..................................................................................................... 47 B-13 Test the Drive Speed - Stowed Position.................................................................................... 47 B-14 Test the Drive Speed - Raised or Extended Position........................................................................ 48 B-15 Test the Alarm Package (if equipped)...................................................................................... 48 B-16 Test the Turntable Rotation Stop.......................................................................................... 49 B-17 Check the Electrical Contactors........................................................................................... 50 B-18 Perform Hydraulic Oil Analysis............................................................................................ 50 B-19 Perform Engine Maintenance................................................................................................ 51 Checklist C Procedures............................................................................................................. 52 C-1 Perform Engine Maintenance................................................................................................. 52 C-2 Grease the Platform Overload Mechanism (if equipped)....................................................................... 52 C-3 Test the Platform Overload System (if equipped)............................................................................ 53 C-4 Perform Engine Maintenance................................................................................................. 55 Checklist D Procedures............................................................................................................. 56 D-1 Check the Primary Boom Wear Pads........................................................................................... 56 D-2 Check the Turntable Rotation Bearing Bolts................................................................................. 56 D-3 Check the Free-wheel Configuration......................................................................................... 58 D-4 Replace the Drive Hub Oil.................................................................................................. 59 D-5 Replace the Hydraulic Tank Return Filter................................................................................... 60 D-6 Inspect for Turntable Bearing Wear......................................................................................... 60 D-7 Calibrate the Platform Overload System (if equipped)....................................................................... 62 D-8 Perform Engine Maintenance................................................................................................. 63 D-9 Perform Engine Maintenance................................................................................................. 64 Checklist E Procedures............................................................................................................. 65 E-1 Test or Replace the Hydraulic Oil.......................................................................................... 65 E-2 Grease the Steer Axle Wheel Bearings....................................................................................... 66 E-3 Perform Engine Maintenance................................................................................................. 68 Repair Procedures...................................................................................................................... 69 Platform Controls.................................................................................................................. 70 1-1 Controllers................................................................................................................ 70 Platform Components................................................................................................................ 72 2-1 Platform Leveling Slave Cylinder........................................................................................... 72 2-2 Platform Rotator........................................................................................................... 73 Jib Boom Components, Z-45/25J...................................................................................................... 75 3-1 Jib Boom................................................................................................................... 75 3-2 Jib Boom Lift Cylinder..................................................................................................... 76 Primary Boom Components............................................................................................................ 78 4-1 Cable Track................................................................................................................ 78 4-2 Primary Boom............................................................................................................... 82 4-3 Primary Boom Lift Cylinder................................................................................................. 85 4-4 Primary Boom Extension Cylinder............................................................................................ 86 4-5 Platform Leveling Master Cylinder.......................................................................................... 87 Secondary Boom Components.......................................................................................................... 88 5-1 Secondary Boom............................................................................................................. 89 5-2 Secondary Boom Lift Cylinders.............................................................................................. 94 Kubota Z482-E Engine............................................................................................................... 95 6-1 Timing Adjustment.......................................................................................................... 95 6-2 RPM Adjustment............................................................................................................. 95 6-3 Engine Drive Pulley........................................................................................................ 95 Generator.......................................................................................................................... 97 7-1 Generator Pulley........................................................................................................... 97 7-2 Generator Belts............................................................................................................ 98 7-3 Generator Voltage Regulator................................................................................................ 98 Hydraulic Pumps....................................................................................................................101 8-1 Auxiliary Pump.............................................................................................................101 8-2 Function Pump..............................................................................................................101 Manifolds..........................................................................................................................102 9-1 Function Manifold Components (before serial number 17841)..................................................................102 9-2 Function Manifold Components (from serial number 17841 to 20379)...........................................................106 9-3 Function Manifold Components (from serial number 20380 to 22565)...........................................................108 9-4 Function Manifold Components (from serial number 22566 to 23235)...........................................................110 9-5 Valve Adjustments - Function Manifold......................................................................................112 9-6 Jib Boom / Platform Rotate Manifold Components.............................................................................114 9-7 Turntable Rotation Manifold Components.....................................................................................115 Turntable Rotation Components......................................................................................................116 10-1 Rotation Hydraulic Motor (before serial number 18367).....................................................................116 10-2 Turntable Rotation Assembly (from serial number 18367 to 23235)...........................................................118 Motor Controller...................................................................................................................120 11-1 Motor Controller..........................................................................................................120 Fault Codes............................................................................................................................121 Fault Code Chart...................................................................................................................123 Schematics.............................................................................................................................127 Electrical Symbols Legend..........................................................................................................128 Hydraulic Symbols Legend...........................................................................................................129 Power Cable Diagram (before serial number 16839)...................................................................................132 Power Cable Diagram (from serial number 16840 to 21179)............................................................................133 Power Cable Diagram (from serial number 21180 to 22050)............................................................................136 Power Cable Diagram (from serial number 22051 to 23235)............................................................................137 Engine Panel Diagram (before serial number 13361)..................................................................................140 Engine Panel Diagram (from serial number 13361 to 14078)...........................................................................141 Engine Panel Diagram (from serial number 14079 to 14650)...........................................................................144 Engine Panel Diagram (from serial number 14651 to 16839)...........................................................................145 Engine Panel Diagram (from serial number 16840 to 17974)...........................................................................148 Engine Panel Diagram (from serial number 17975 to 21180)...........................................................................149 Engine Panel Diagram (from serial number 21181 to 22050)...........................................................................152 Engine Panel Diagram (from serial number 22051 to 23235)...........................................................................153 Electrical Schematic, Z-45/25 (before serial number 13361).........................................................................156 Electrical Schematic, Z-45/25 (from serial number 13361 to 14078)..................................................................160 Electrical Schematic, Z-45/25 (from serial number 14079 to 14650)..................................................................164 Electrical Schematic, Z-45/25 (from serial number 14651 to 16839)..................................................................168 Electrical Schematic, Z-45/25 (from serial number 16840 to 17974)..................................................................172 Electrical Schematic, Z-45/25 (from serial number 17975 to 21180)..................................................................176 Electrical Schematic, Z-45/25 (from serial number 21180 to 22050)..................................................................180 Electrical Schematic, Z-45/25, ANSI and CSA Models (from serial number 22051 to 23235).............................................184 Electrical Schematic, Z-45/25, CE Models (from serial number 22051 to 23235).......................................................188 Electrical Schematic, Z-45/25J (before serial number 13361)........................................................................192 Electrical Schematic, Z-45/25J (from serial number 13361 to 14078).................................................................196 Electrical Schematic, Z-45/25J (from serial number 14079 to 14650).................................................................200 Electrical Schematic, Z-45/25J (from serial number 14651 to 16839).................................................................204 Electrical Schematic, Z-45/25J (from serial number 16840 to 17974).................................................................208 Electrical Schematic, Z-45/25J (from serial number 17975 to 21180).................................................................212 Electrical Schematic, Z-45/25J (from serial number 21180 to 22050).................................................................216 Electrical Schematic, Z-45/25J, ANSI and CSA Models (from serial number 22051 to 23235)............................................220 Electrical Schematic, Z-45/25J, CE Models (from serial number 22051 to 23235)......................................................224 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25 (before serial number 13361).............................................228 Ground Control Box Switch Panel Wiring Diagram, Z-45/25 (before serial number 13361)...............................................229 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25 (from serial number 13361 to 14078)......................................232 Ground Control Box Switch Panel Wiring Diagram, Z-45/25 (from serial number 13361 to 14078)........................................233 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25 (from serial number 14079 to 14650)......................................236 Ground Control Box Switch Panel Wiring Diagram, Z-45/25 (from serial number 14079 to 14650)........................................237 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25 (from serial number 14651 to 16839)......................................240 Ground Control Box Switch Panel Wiring Diagram, Z-45/25 (from serial number 14651 to 16839)........................................241 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25 (from serial number 16840 to 17974)......................................244 Ground Control Box Switch Panel Wiring Diagram, Z-45/25 (from serial number 16840 to 17974)........................................245 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25 (from serial number 17975 to 21180)......................................248 Ground Control Box Switch Panel Wiring Diagram, Z-45/25 (from serial number 17975 to 21180)........................................249 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25 (from serial number 21181 to 22050)......................................252 Ground Control Box Switch Panel Wiring Diagram, Z-45/25 (from serial number 21181 to 22050)........................................253 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25, ANSI and CSA Models (from serial number 22051 to 23235).................256 Ground Control Box Switch Panel Wiring Diagram, Z-45/25, ANSI and CSA Models (from serial number 22051 to 23235)...................257 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25, CE Models (from serial number 22051 to 23235)...........................260 Ground Control Box Switch Panel Wiring Diagram, Z-45/25, CE Models (from serial number 22051 to 23235).............................261 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J (before serial number 13361)............................................264 Ground Control Box Switch Panel Wiring Diagram, Z-45/25J (before serial number 13361)..............................................265 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J (from serial number 13361 to 14078).....................................268 Ground Control Box Switch Panel Wiring Diagram, Z-45/25J (from serial number 13361 to 14078).......................................269 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J (from serial number 14079 to 14650).....................................272 Ground Control Box Switch Panel Wiring Diagram, Z-45/25J (from serial number 14079 to 14650).......................................273 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J (from serial number 14651 to 16839).....................................276 Ground Control Box Switch Panel Wiring Diagram, Z-45/25J (from serial number 14651 to 16839).......................................277 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J (from serial number 16840 to 17974).....................................280 Ground Control Box Switch Panel Wiring Diagram, Z-45/25J (from serial number 16840 to 17974).......................................281 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J (from serial number 17975 to 21180).....................................284 Ground Control Box Switch Panel Wiring Diagram, Z-45/25J (from serial number 17975 to 21180).......................................285 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J (from serial number 21181 to 22050).....................................288 Ground Control Box Switch Panel Wiring Diagram, Z-45/25J (from serial number 21181 to 22050).......................................289 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J, ANSI and CSA Models (from serial number 22051 to 23235)................292 Ground Control Box Switch Panel Wiring Diagram, Z-45/25J, ANSI and CSA Models (from serial number 22051 to 23235)..................293 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J, CE Models (from serial number 22051 to 23235)..........................296 Ground Control Box Switch Panel Wiring Diagram, Z-45/25J, CE Models (from serial number 22051 to 23235)............................297 Platform Control Box Wiring Diagram, Z-45/25 (before serial number 13361)..........................................................300 Platform Control Box Wiring Diagram, Z-45/25 (with Platform Load Sense and LVI/BCI Option) (before serial number 13361)............301 Platform Control Box Wiring Diagram, Z-45/25 (from serial number 13361 to 14078)...................................................304 Platform Control Box Wiring Diagram, Z-45/25 (with Platform Load Sense and LVI/BCI Option)(from serial number 13361 to 14078)......305 Platform Control Box Wiring Diagram, Z-45/25 (from serial number 14079 to 14650)...................................................308 Platform Control Box Wiring Diagram, Z-45/25 (with Platform Load Sense and LVI/BCI Option)(from serial number 14079 to 14650)......309 Platform Control Box Wiring Diagram, Z-45/25 (from serial number 14651 to 16839)...................................................312 Platform Control Box Wiring Diagram, Z-45/25 with LVI/BCI Option (from serial number 14651 to 16839)...............................313 Platform Control Box Wiring Diagram, Z-45/25 (from serial number 16840 to 17974)...................................................316 Platform Control Box Wiring Diagram, Z-45/25 with LVI/BCI Option (from serial number 16840 to 17974)...............................317 Platform Control Box Wiring Diagram, Z-45/25 (from serial number 17975 to 21180)...................................................320 Platform Control Box Wiring Diagram, Z-45/25 with LVI/BCI Option (from serial number 17975 to 21180)...............................321 Platform Control Box Wiring Diagram, Z-45/25 (from serial number 21181 to 22050)...................................................324 Platform Control Box Wiring Diagram, Z-45/25 with LVI/BCI Option (from serial number 21181 to 22050)...............................325 Platform Control Box Wiring Diagram, Z-45/25 (from serial number 22051 to 23235)...................................................328 Platform Control Box Wiring Diagram, Z-45/25 with LVI/BCI Option (from serial number 22051 to 23235)...............................329 Platform Control Box Wiring Diagram, Z-45/25J (before serial number 13361).........................................................332 Platform Control Box Wiring Diagram, Z-45/25J (with Platform Load Sense and LVI/BCI Option) (before serial number 13361)...........333 Platform Control Box Wiring Diagram, Z-45/25J (from serial number 13361 to 14078)..................................................336 Platform Control Box Wiring Diagram, Z-45/25J (with Platform Load Sense and LVI/BCI Option) (from serial number 13361 to 14078)....337 Platform Control Box Wiring Diagram, Z-45/25J (from serial number 14079 to 14650)..................................................340 Platform Control Box Wiring Diagram, Z-45/25J (with Platform Load Sense and LVI/BCI Option) (from serial number 14079 to 14650)....341 Platform Control Box Wiring Diagram, Z-45/25J (from serial number 14651 to 16839)..................................................344 Platform Control Box Wiring Diagram, Z-45/25J with LVI/BCI Option (from serial number 14651 to 16839)..............................345 Platform Control Box Wiring Diagram, Z-45/25J (from serial number 16840 to 17974)..................................................348 Platform Control Box Wiring Diagram, Z-45/25J with LVI/BCI Option (from serial number 16840 to 17974)..............................349 Platform Control Box Wiring Diagram, Z-45/25J (from serial number 17975 to 21180)..................................................352 Platform Control Box Wiring Diagram, Z-45/25J with LVI/BCI Option (from serial number 17975 to 21180)..............................353 Platform Control Box Wiring Diagram, Z-45/25J (from serial number 21181 to 22050)..................................................356 Platform Control Box Wiring Diagram, Z-45/25J with LVI/BCI Option (from serial number 21181 to 22050)..............................357 Platform Control Box Wiring Diagram, Z-45/25J (from serial number 22051 to 23235)..................................................360 Platform Control Box Wiring Diagram, Z-45/25J with LVI/BCI Option (from serial number 22051 to 23235)..............................361 Hydraulic Schematic (before serial number 16962)...................................................................................364 Hydraulic Schematic (from serial number 16962 to 20379)............................................................................365 Hydraulic Schematic (from serial number 20380 to 22565)............................................................................368 Hydraulic Schematic (from serial number 22566 to 23235)............................................................................369
S.S 05/24
