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Genie Z-45/25 Z-45/25J Bi-Energy Power Service Manual – PDF DOWNLOAD
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Genie Z-45/25 Z-45/25J Bi-Energy Power Service Manual – PDF DOWNLOAD
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Description
Genie Z-45/25 Z-45/25J Bi-Energy Power Service Manual – PDF DOWNLOAD
Language : English
Pages : 175
Downloadable : Yes
File Type : PDF
Table of Contents:
Genie Z-45/25 Z-45/25J Bi-Energy Power Service Manual – 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-E2B Engine...................................................................................................... 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.............................................................................. 39 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.................................................................................... 42 B-10 Test the Platform Self-leveling.................................................................................... 42 B-11 Test the Engine Idle Select........................................................................................ 43 B-12 Test the Drive Brakes.............................................................................................. 44 B-13 Test the Drive Speed - Stowed Position............................................................................. 44 B-14 Test the Drive Speed - Raised or Extended Position................................................................. 45 B-15 Test the Alarm Package (if equipped)............................................................................... 45 B-16 Check the Electrical Contactors.................................................................................... 47 B-17 Perform Hydraulic Oil Analysis..................................................................................... 47 B-18 Perform Engine Maintenance......................................................................................... 48 Checklist C Procedures...................................................................................................... 49 C-1 Perform Engine Maintenance.......................................................................................... 49 C-2 Grease the Platform Overload Mechanism (if equipped)................................................................ 49 C-3 Test the Platform Overload System (if equipped)..................................................................... 50 C-4 Perform Engine Maintenance.......................................................................................... 52 Checklist D Procedures...................................................................................................... 53 D-1 Check the Primary Boom Wear Pads.................................................................................... 53 D-2 Check the Free-wheel Configuration.................................................................................. 53 D-3 Replace the Drive Hub Oil........................................................................................... 54 D-4 Replace the Hydraulic Tank Return Filter............................................................................ 55 D-5 Calibrate the Platform Overload System (if equipped)................................................................ 56 D-6 Check the Turntable Rotation Bearing Bolts.......................................................................... 58 D-7 Inspect for Turntable Bearing Wear.................................................................................. 59 D-8 Perform Engine Maintenance.......................................................................................... 61 Checklist E Procedures...................................................................................................... 62 E-1 Test or Replace the Hydraulic Oil................................................................................... 62 E-2 Grease the Steer Axle Wheel Bearings................................................................................ 63 E-3 Perform Engine Maintenance.......................................................................................... 65 E-4 Perform Engine Maintenance.......................................................................................... 65 Repair Procedures............................................................................................................... 67 Platform Controls........................................................................................................... 68 1-1 Controllers......................................................................................................... 68 Platform Components......................................................................................................... 70 2-1 Platform Leveling Slave Cylinder.................................................................................... 70 2-2 Platform Rotator.................................................................................................... 71 Jib Boom Components, Z-45/25J............................................................................................... 73 3-1 Jib Boom............................................................................................................ 73 3-2 Jib Boom Lift Cylinder.............................................................................................. 74 Primary Boom Components..................................................................................................... 76 4-1 Cable Track......................................................................................................... 76 4-2 Primary Boom........................................................................................................ 80 4-3 Primary Boom Lift Cylinder.......................................................................................... 83 4-4 Primary Boom Extension Cylinder..................................................................................... 84 4-5 Platform Leveling Master Cylinder................................................................................... 85 Secondary Boom Components................................................................................................... 86 5-1 Secondary Boom...................................................................................................... 87 5-2 Secondary Boom Lift Cylinders....................................................................................... 92 Kubota Z482-E2B Engine...................................................................................................... 93 6-1 Timing Adjustment................................................................................................... 93 6-2 RPM Adjustment...................................................................................................... 93 6-3 Engine Drive Pulley................................................................................................. 93 Generator................................................................................................................... 95 7-1 Generator Pulley.................................................................................................... 95 7-2 Generator Belts..................................................................................................... 96 7-3 Generator Voltage Regulator......................................................................................... 96 Hydraulic Pumps............................................................................................................. 99 8-1 Auxiliary Pump...................................................................................................... 99 8-2 Function Pump.......................................................................................................100 Manifolds...................................................................................................................102 9-1 Function Manifold Components........................................................................................102 9-2 Valve Adjustments - Function Manifold...............................................................................104 9-3 Jib Boom / Platform Rotate Manifold Components......................................................................105 9-4 Turntable Rotation Manifold Components..............................................................................106 9-5 Valve Coils.........................................................................................................107 Turntable Rotation Components...............................................................................................109 10-1 Turntable Rotation Assembly........................................................................................109 Motor Controller............................................................................................................111 11-1 Motor Controller...................................................................................................111 Fault Codes.....................................................................................................................113 Fault Code Chart............................................................................................................115 Schematics......................................................................................................................119 Electrical Symbols Legend...................................................................................................120 Hydraulic Symbols Legend....................................................................................................121 Electrical Schematic, (ANSI / CSA / AS) (from serial number Z452507-31015 to Z452507A-34514)...............................124 Ground Control Box Terminal Strip Wiring Diagram, (ANSI / CSA / AS) (from serial number Z452507-31015 to Z452507A-34514)....128 Ground Control Box Switch Panel Wiring Diagram, (ANSI / CSA / AS) (from serial number Z452507-31015 to Z452507A-34514)......129 Platform Control Box Wiring Diagram, (ANSI / CSA / AS) (from serial number Z452507-31015 to Z452507A-34514).................131 Electrical Schematic, (CE) (from serial number Z452507-31015 to Z452507A-34514).............................................134 Ground Control Box Terminal Strip Wiring Diagram, (CE) (from serial number Z452507-31015 to Z452507A-34514).................138 Ground Control Box Switch Panel Wiring Diagram, (CE) (from serial number Z452507-31015 to Z452507A-34514)...................139 Platform Control Box Wiring Diagram, (CE) (from serial number Z452507-31015 to Z452507A-34514)..............................141 Electrical Schematic, (ANSI / CSA / AS) (from serial number Z452507A-34515).................................................144 Ground Control Box Terminal Strip Wiring Diagram, (ANSI / CSA / AS) (from serial number Z452507A-34515)....................148 Ground Control Box Switch Panel Wiring Diagram, (ANSI / CSA / AS) (from serial number Z452507A-34515).......................149 Platform Control Box Wiring Diagram, (ANSI / CSA / AS) (from serial number Z452507A-34515)..................................151 Electrical Schematic, (CE) (from serial number Z452507A-34515)..............................................................154 Ground Control Box Terminal Strip Wiring Diagram, (CE) (from serial number Z452507A-34515)..................................158 Ground Control Box Switch Panel Wiring Diagram, (CE) (from serial number Z452507A-34515)....................................159 Platform Control Box Wiring Diagram, (CE) (from serial number Z452507A-34515)...............................................162 Platform Options Wiring Diagram.............................................................................................163 Engine Panel Wiring Diagram.................................................................................................166 Power Panel Wiring Diagram..................................................................................................167 CTE Option Wiring diagram, (CE).............................................................................................170 Charger Interlock Option....................................................................................................171 Hydraulic Schematic.........................................................................................................173 Back Cover......................................................................................................................175 Return to Index................................................................................................................. 0
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