Genie Z-45/25 Z-45/25J Bi-Energy Power Service Manual 110188 – PDF

Description

Genie Z-45/25 Z-45/25J Bi-Energy Power Service Manual 110188 – PDF DOWNLOAD

Language : English
Pages : 169
Downloadable : Yes
File Type : PDF

Table of Contents:

Genie Z-45/25 Z-45/25J Bi-Energy Power Service Manual 110188 – PDF DOWNLOAD

Front Cover............................................................................  1
Introduction...........................................................................  2
Revision History.......................................................................  3
Serial Number Legend...................................................................  5
Safety Rules...........................................................................  6
Table of Contents......................................................................  8
Specifications......................................................................... 15
	Machine Specifications............................................................. 15
	Performance Specifications......................................................... 16
	Hydraulic Specifications........................................................... 17
	Manifold Component Specifications.................................................. 18
	Machine Torque Specifications...................................................... 18
	Kubota Z482-E and Z482-E2B Engines................................................. 19
	Generator.......................................................................... 20
	Generator Torque Specifications.................................................... 20
	Hydraulic Hose and Fitting Torque Specifications................................... 21
	SAE and Metric Fastener Torque Chart............................................... 22
Scheduled Maintenance Procedures....................................................... 23
	Pre-delivery Preparation........................................................... 25
	Maintenance Inspection Report...................................................... 27
	Checklist A Procedures............................................................. 29
		A-1 Perform Pre-operation Inspection........................................... 29
		A-2 Perform Function Tests..................................................... 29
		A-3 Check the Generator Belts and Pulleys...................................... 30
		A-4 Perform 30 Day Service..................................................... 31
		A-5 Perform Engine Maintenance................................................. 32
		A-6 Perform Engine Maintenance................................................. 32
		A-7 Grease the Turntable Rotation Bearing and Rotate Gear...................... 33
		A-8 Perform Engine Maintenance................................................. 33
		A-9 Perform Engine Maintenance................................................. 34
		A-10 Perform Engine Maintenance................................................ 34
	Checklist B Procedures............................................................. 35
		B-1 Check the Radiator......................................................... 35
		B-2 Check the Exhaust System................................................... 35
		B-3 Check the Batteries........................................................ 36
		B-4 Inspect the Electrical Wiring.............................................. 37
		B-5 Check the Lug Nut Torque (including the tires and wheels).................. 38
		B-6 Confirm the Proper Brake Configuration..................................... 38
		B-7 Check the Oil Level in the Drive Hubs...................................... 39
		B-8 Check and Adjust the Engine RPM............................................ 40
		B-9 Test the Ground Control Override........................................... 41
		B-10 Test the Platform Self-leveling........................................... 42
		B-11 Test the Engine Idle Select............................................... 42
		B-12 Test the Drive Brakes..................................................... 43
		B-13 Test the Drive Speed - Stowed Position.................................... 43
		B-14 Test the Drive Speed - Raised or Extended Position........................ 44
		B-15 Test the Alarm Package (if equipped)...................................... 44
		B-16 Check the Electrical Contactors........................................... 45
		B-17 Perform Hydraulic Oil Analysis............................................ 46
		B-18 Perform Engine Maintenance................................................ 46
	Checklist C Procedures............................................................. 47
		C-1 Perform Engine Maintenance................................................. 47
		C-2 Grease the Platform Overload Mechanism (if equipped)....................... 47
		C-3 Test the Platform Overload System (if equipped)............................ 48
		C-4 Perform Engine Maintenance................................................. 50
	Checklist D Procedures............................................................. 51
		D-1 Check the Primary Boom Wear Pads........................................... 51
		D-2 Check the Free-wheel Configuration......................................... 51
		D-3 Replace the Drive Hub Oil.................................................. 52
		D-4 Replace the Hydraulic Tank Return Filter................................... 53
		D-5 Calibrate the Platform Overload System (if equipped)....................... 54
		D-6 Check the Turntable Rotation Bearing Bolts................................. 56
		D-7 Inspect for Turntable Bearing Wear......................................... 57
		D-8 Perform Engine Maintenance................................................. 59
		D-9 Perform Engine Maintenance................................................. 59
	Checklist E Procedures............................................................. 60
		E-1 Test or Replace the Hydraulic Oil.......................................... 60
		E-2 Grease the Steer Axle Wheel Bearings....................................... 61
		E-3 Perform Engine Maintenance................................................. 63
		E-4 Perform Engine Maintenance, Z4822-E2B Engine............................... 63
Repair Procedures...................................................................... 65
	Platform Controls.................................................................. 66
		1-1 Controllers................................................................ 66
	Platform Components................................................................ 68
		2-1 Platform Leveling Slave Cylinder........................................... 68
		2-2 Platform Rotator........................................................... 69
	Jib Boom Components, Z-45/25J...................................................... 71
		3-1 Jib Boom................................................................... 71
		3-2 Jib Boom Lift Cylinder..................................................... 72
	Primary Boom Components............................................................ 74
		4-1 Cable Track................................................................ 74
		4-2 Primary Boom............................................................... 78
		4-3 Primary Boom Lift Cylinder................................................. 81
		4-4 Primary Boom Extension Cylinder............................................ 82
		4-5 Platform Leveling Master Cylinder.......................................... 83
	Secondary Boom Components.......................................................... 84
		5-1 Secondary Boom............................................................. 85
		5-2 Secondary Boom Lift Cylinders.............................................. 90
	Kubota Z482-E Engine............................................................... 91
		6-1 Timing Adjustment.......................................................... 91
		6-2 RPM Adjustment............................................................. 91
		6-3 Engine Drive Pulley........................................................ 91
	Generator.......................................................................... 93
		7-1 Generator Pulley........................................................... 93
		7-2 Generator Belts............................................................ 94
		7-3 Generator Voltage Regulator................................................ 94
	Hydraulic Pumps.................................................................... 97
		8-1 Auxiliary Pump............................................................. 97
		8-2 Function Pump.............................................................. 98
	Manifolds..........................................................................100
		9-1 Function Manifold Components...............................................100
		9-2 Valve Adjustments - Function Manifold......................................102
		9-3 Jib Boom / Platform Rotate Manifold Components.............................103
		9-4 Turntable Rotation Manifold Components.....................................104
		9-5 Valve Coils................................................................105
	Turntable Rotation Components......................................................107
		10-1 Turntable Rotation Assembly...............................................107
	Motor Controller...................................................................109
		11-1 Motor Controller..........................................................109
Fault Codes............................................................................111
	Fault Code Chart...................................................................113
Schematics.............................................................................117
	Electrical Symbols Legend..........................................................118
	Hydraulic Symbols Legend...........................................................119
	Power Cable Diagram................................................................122
	Engine Panel Diagram...............................................................123
	Electrical Schematic, Z-45/25, ANSI and CSA Models.................................126
	Electrical Schematic, Z-45/25, CE Models...........................................130
	Electrical Schematic, Z-45/25J, ANSI and CSA Models................................134
	Electrical Schematic, Z-45/25J, CE Models..........................................138
	Ground Control Box Terminal Strip Wiring Diagram, Z-45/25, ANSI and CSA Models.....142
	Ground Control Box Switch Panel Wiring Diagram, Z-45/25, ANSI and CSA Models.......143
	Ground Control Box Terminal Strip Wiring Diagram, Z-45/25, CE Models...............146
	Ground Control Box Switch Panel Wiring Diagram, Z-45/25, CE Models.................147
	Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J, ANSI and CSA Models....150
	Ground Control Box Switch Panel Wiring Diagram, Z-45/25J, ANSI and CSA Models......151
	Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J, CE Models..............154
	Ground Control Box Switch Panel Wiring Diagram, Z-45/25J, CE Models................155
	Platform Control Box Wiring Diagram, Z-45/25.......................................158
	Platform Control Box Wiring Diagram, Z-45/25 with LVI/BCI Option...................159
	Platform Control Box Wiring Diagram, Z-45/25J......................................162
	Platform Control Box Wiring Diagram, Z-45/25J with LVI/BCI Option..................163
	Platform Level Cutout, CTE Option..................................................166
	Hydraulic Schematic................................................................167
Back Cover.............................................................................169

S.S 04/24