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Genie Z-45/25 Z-45/25J Bi-Energy Power Service Manual 237062 – PDF DOWNLOAD
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Genie Z-45/25 Z-45/25J Bi-Energy Power Service Manual 237062 – PDF DOWNLOAD
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Description
Genie Z-45/25 Z-45/25J Bi-Energy Power Service Manual 237062 – PDF DOWNLOAD
Language : English
Pages : 213
Downloadable : Yes
File Type : PDF
Table of Contents:
Genie Z-45/25 Z-45/25J Bi-Energy Power Service Manual 237062 – PDF DOWNLOAD
Front Cover..................................................................................................................... 1 Introduction.................................................................................................................... 2 Revision History................................................................................................................ 3 Serial Number Legend............................................................................................................ 5 Safety Rules.................................................................................................................... 6 Table of Contents............................................................................................................... 8 Specifications.................................................................................................................. 17 Machine Specifications...................................................................................................... 17 Performance Specifications.................................................................................................. 18 Hydraulic Specifications.................................................................................................... 19 Manifold Component Specifications........................................................................................... 20 Machine Torque Specifications............................................................................................... 20 Kubota Z482-E2B Engine...................................................................................................... 21 Generator................................................................................................................... 22 Generator Torque Specifications............................................................................................. 22 Hydraulic Hose and Fitting Torque Specifications............................................................................ 23 SAE and Metric Fastener Torque Chart........................................................................................ 25 Scheduled Maintenance Procedures................................................................................................ 27 Pre-delivery Preparation.................................................................................................... 29 Maintenance Inspection Report............................................................................................... 31 Checklist A Procedures...................................................................................................... 33 A-1 Inspect Manuals and Decals ......................................................................................... 33 A-2 Perform Pre-operation Inspection.................................................................................... 34 A-3 Perform Function Tests............................................................................................. 34 A-4 Check the Generator Belts and Pulleys.............................................................................. 35 A-5 Perform 30 Day Service.............................................................................................. 36 A-6 Perform Engine Maintenance.......................................................................................... 37 A-7 Perform Engine Maintenance.......................................................................................... 37 A-8 Grease the Turntable Rotation Bearing and Rotate Gear............................................................... 38 A-9 Perform Engine Maintenance.......................................................................................... 38 A-10 Perform Engine Maintenance......................................................................................... 39 A-11 Perform Engine Maintenance........................................................................................ 39 Checklist B Procedures...................................................................................................... 40 B-1 Check the Radiator.................................................................................................. 40 B-2 Check the Exhaust System............................................................................................ 40 B-3 Check the Batteries................................................................................................. 41 B-4 Inspect the Electrical Wiring....................................................................................... 42 B-5 Check the Lug Nut Torque (including the tires and wheels)........................................................... 43 B-6 Confirm the Proper Brake Configuration.............................................................................. 44 B-7 Check the Oil Level in the Drive Hubs............................................................................... 44 B-8 Check and Adjust the Engine RPM..................................................................................... 45 B-9 Test the Ground Control Override.................................................................................... 47 B-10 Test the Platform Self-leveling.................................................................................... 47 B-11 Test the Engine Idle Select........................................................................................ 48 B-12 Test the Drive Brakes.............................................................................................. 49 B-13 Test the Drive Speed - Stowed Position............................................................................. 49 B-14 Test the Drive Speed - Raised or Extended Position................................................................. 50 B-15 Test the Alarm Package (if equipped)............................................................................... 50 B-16 Check the Electrical Contactors.................................................................................... 52 B-17 Perform Hydraulic Oil Analysis..................................................................................... 52 B-18 Test the Emergency Power System ................................................................................... 53 B-19 Perform Engine Maintenance........................................................................................ 54 Checklist C Procedures...................................................................................................... 55 C-1 Perform Engine Maintenance.......................................................................................... 55 C-2 Grease the Platform Overload Mechanism (if equipped)................................................................ 55 C-3 Test the Platform Overload System (if equipped)..................................................................... 56 C-4 Perform Engine Maintenance.......................................................................................... 58 Checklist D Procedures...................................................................................................... 59 D-1 Check the Primary Boom Wear Pads.................................................................................... 59 D-2 Check the Free-wheel Configuration.................................................................................. 59 D-3 Replace the Drive Hub Oil........................................................................................... 60 D-4 Replace the Hydraulic Tank Return Filter............................................................................ 61 D-5 Calibrate the Platform Overload System (if equipped)................................................................ 62 D-6 Check the Turntable Rotation Bearing Bolts.......................................................................... 64 D-7 Inspect for Turntable Bearing Wear.................................................................................. 65 D-8 Perform Engine Maintenance.......................................................................................... 67 Checklist E Procedures...................................................................................................... 68 E-1 Test or Replace the Hydraulic Oil................................................................................... 68 E-2 Grease the Steer Axle Wheel Bearings................................................................................ 69 E-3 Perform Engine Maintenance.......................................................................................... 71 E-4 Perform Engine Maintenance.......................................................................................... 71 Repair Procedures............................................................................................................... 73 Platform Controls........................................................................................................... 74 1-1 Controllers......................................................................................................... 74 Platform Components......................................................................................................... 76 2-1 Platform Leveling Slave Cylinder.................................................................................... 76 2-2 Platform Rotator.................................................................................................... 77 Jib Boom Components, Z-45/25J............................................................................................... 79 3-1 Jib Boom............................................................................................................ 79 3-2 Jib Boom Lift Cylinder.............................................................................................. 80 Primary Boom Components..................................................................................................... 82 4-1 Cable Track......................................................................................................... 82 4-2 Primary Boom........................................................................................................ 86 4-3 Primary Boom Lift Cylinder.......................................................................................... 89 4-4 Primary Boom Extension Cylinder..................................................................................... 90 4-5 Platform Leveling Master Cylinder................................................................................... 91 Secondary Boom Components................................................................................................... 92 5-1 Secondary Boom...................................................................................................... 93 5-2 Secondary Boom Lift Cylinders....................................................................................... 98 Kubota Z482-E2B Engine...................................................................................................... 99 6-1 Timing Adjustment................................................................................................... 99 6-2 RPM Adjustment...................................................................................................... 99 6-3 Engine Drive Pulley................................................................................................. 99 Generator...................................................................................................................101 7-1 Generator Pulley....................................................................................................101 7-2 Generator Belts.....................................................................................................102 7-3 Generator Voltage Regulator.........................................................................................102 Hydraulic Pumps.............................................................................................................105 8-1 Auxiliary Pump......................................................................................................105 8-2 Function Pump.......................................................................................................106 Manifolds...................................................................................................................108 9-1 Function Manifold Components........................................................................................108 9-2 Valve Adjustments - Function Manifold...............................................................................110 9-3 Jib Boom / Platform Rotate Manifold Components......................................................................111 9-4 Turntable Rotation Manifold Components..............................................................................112 9-5 Valve Coils.........................................................................................................113 Turntable Rotation Components...............................................................................................115 10-1 Turntable Rotation Assembly........................................................................................115 Motor Controller............................................................................................................117 11-1 Motor Controller...................................................................................................117 Fault Codes.....................................................................................................................119 Fault Code Chart............................................................................................................121 Schematics......................................................................................................................125 Hydraulic Symbols Legend....................................................................................................127 Electrical Symbols Legend...................................................................................................126 Electrical Schematics - ANSI / CSA Markets..................................................................................130 Electrical Schematic, (ANSI / CSA) (from serial number Z452510A-39314 to Z452513A-45734)...............................130 Ground Control Box Terminal Strip Wiring Diagram, (ANSI / CSA) (from serial number Z452510A-39314 to Z452513A-45734)....134 Ground Control Box Switch Panel Wiring Diagram, (ANSI / CSA) (from serial number Z452510A-39314 to Z452513A-45734)......135 Platform Control Box Wiring Diagram, (ANSI / CSA) (from serial number Z452510A-39314 to Z452513A-45734).................137 Electrical Schematic, (ANSI / CSA) (from serial number Z452513A-45735)..................................................140 Ground Control Box Terminal Strip Wiring Diagram, (ANSI / CSA) (from serial number Z452513A-45735)......................144 Ground Control Box Switch Panel Wiring Diagram, (ANS / CSA) (from serial number Z452513A-45735).........................145 Platform Control Box Wiring Diagram, (ANSI / CSA) (from serial number Z452513A-45735)...................................147 Electrical Schematics - CE Markets..........................................................................................150 Electrical Schematic, (CE) (from serial number Z452510A-39314 to Z452513A-45734)........................................150 Ground Control Box Terminal Strip Wiring Diagram, (CE) (from serial number Z452510A-39314 to Z452513A-45734)............154 Ground Control Box Switch Panel Wiring Diagram, (CE) (from serial number Z452510A-39314 to Z452513A-45734)..............155 Platform Control Box Wiring Diagram, (CE) (from serial number Z452510A-39314 to Z452513A-45734).........................157 Electrical Schematic, (CE) (from serial number Z452513A-45735...........................................................160 Ground Control Box Terminal Strip Wiring Diagram, (CE) (from serial number Z452513A-45735).............................. 0 Ground Control Box Switch Panel Wiring Diagram, (CE) (from serial number Z452513A-45735)................................165 Platform Control Box Wiring Diagram, (CE) (from serial number Z452513A-45735)...........................................167 Electrical Schematics - AS Markets..........................................................................................170 Electrical Schematic, (AS) (from serial number Z452510A-39314 to Z452511A-40559)........................................170 Ground Control Box Terminal Strip Wiring Diagram, (AS) (from serial number Z452510A-39314 to Z452511A-40559)............174 Ground Control Box Switch Panel Wiring Diagram, (AS) (from serial number Z452510A-39314 to Z452511A-40559)..............175 Platform Control Box Wiring Diagram, (AS) (from serial number Z452510A-39314 to Z452511A-40559).........................177 Electrical Schematic, (AS) (from serial number Z452511A-40560 to Z452513A-45734)........................................180 Ground Control Box Terminal Strip Wiring Diagram, (AS) (from serial number Z452511A-40560 to Z452513A-45734)............184 Ground Control Box Switch Panel Wiring Diagram, (AS) (from serial number Z452511A-40560 to z452513A-45734)..............185 Platform Control Box Wiring Diagram, (AS) (from serial number Z452511A-40560 to Z452513A-45734).........................187 Electrical Schematic, (AS) (from serial number Z452513A-45735)..........................................................190 Ground Control Box Terminal Strip Wiring Diagram, (AS) (from serial number Z452513A-45735)..............................194 Ground Control Box Switch Panel Wiring Diagram, (AS) (from serial number Z452513A-45735.................................195 Platform Control Box Wiring Diagram, )AS) (from serial number Z452513A-45735)...........................................197 Platform Options Wiring Diagram (from serial number Z452510A-39314 to Z452513A-45734).......................................200 Platform Options Wiring Diagram (from serial number Z452513A-45735).........................................................201 Engine Panel Wiring Diagram.................................................................................................204 Power Panel Wiring Diagram..................................................................................................205 CTE Option Wiring diagram, (CE).............................................................................................208 Charger Interlock Option....................................................................................................209 Hydraulic Schematic.........................................................................................................211 Back Cover......................................................................................................................213
S.S 05/24
