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Genie Z-45/25 Z-45/25J DC Power Service Manual 106726 – PDF DOWNLOAD
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Genie Z-45/25 Z-45/25J DC Power Service Manual 106726 – PDF DOWNLOAD
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Description
Genie Z-45/25 Z-45/25J DC Power Service Manual 106726 – PDF DOWNLOAD
Language : English
Pages : 331
Downloadable : Yes
File Type : PDF
Table of Contents:
Genie Z-45/25 Z-45/25J DC Power Service Manual 106726 – PDF DOWNLOAD
Front Cover............................................................................................................................ 1 Introduction........................................................................................................................... 2 Serial Number Legend................................................................................................................... 3 Safety Rules........................................................................................................................... 5 Table of Contents...................................................................................................................... 7 Specifications......................................................................................................................... 17 Machine Specifications............................................................................................................. 17 Performance Specifications......................................................................................................... 18 Hydraulic Specifications........................................................................................................... 19 Manifold Component Specifications.................................................................................................. 20 Machine Torque Specifications...................................................................................................... 20 Hydraulic Hose and Fitting Torque Specifications................................................................................... 21 SAE and Metric Fasteners Torque Charts............................................................................................. 22 Scheduled Maintenance Procedures....................................................................................................... 23 Pre-delivery Preparation........................................................................................................... 25 Maintenance Inspection Report...................................................................................................... 27 Checklist A Procedures............................................................................................................. 28 A-1 Perform Pre-operation Inspection........................................................................................... 28 A-2 Perform Function Tests..................................................................................................... 28 A-3 Perform 30 Day Service..................................................................................................... 29 A-4 Grease the Turntable Rotation Bearing and Rotate Gear...................................................................... 29 Checklist B Procedures............................................................................................................. 30 B-1 Check the Batteries........................................................................................................ 30 B-2 Inspect the Electrical Wiring.............................................................................................. 31 B-3 Check the Lug Nut Torque (including the tires and wheels).................................................................. 32 B-4 Confirm the Proper Brake Configuration..................................................................................... 32 B-5 Check the Oil Level in the Drive Hubs...................................................................................... 33 B-6 Test the Ground Control Override........................................................................................... 34 B-7 Test the Platform Self-leveling............................................................................................ 34 B-8 Test the Drive Brakes...................................................................................................... 35 B-9 Test the Drive Speed - Stowed Position..................................................................................... 35 B-10 Test the Drive Speed - Raised or Extended Position........................................................................ 36 B-11 Test the Alarm Package (if equipped)...................................................................................... 36 B-12 Test the Turntable Rotation Stop.......................................................................................... 37 B-13 Check the Electrical Contactors........................................................................................... 38 B-14 Perform Hydraulic Oil Analysis............................................................................................ 38 Checklist C Procedures............................................................................................................. 39 C-1 Grease the Platform Overload Mechanism (if equipped)....................................................................... 39 C-2 Test the Platform Overload System (if equipped)............................................................................ 39 Checklist D Procedures............................................................................................................. 42 D-1 Check the Primary Boom Wear Pads........................................................................................... 42 D-2 Check the Turntable Rotation Bearing Bolts................................................................................. 42 D-3 Check the Free-wheel Configuration......................................................................................... 44 D-4 Replace the Drive Hub Oil.................................................................................................. 45 D-5 Replace the Hydraulic Tank Return Filter................................................................................... 46 D-6 Calibrate the Platform Overload System (if equipped)....................................................................... 46 Checklist E Procedures............................................................................................................. 48 E-1 Test or Replace the Hydraulic Oil.......................................................................................... 48 E-2 Grease the Steer Axle Wheel Bearings....................................................................................... 49 Repair Procedures...................................................................................................................... 51 Platform Controls.................................................................................................................. 52 1-1 Controllers................................................................................................................ 52 Platform Components................................................................................................................ 54 2-1 Platform Leveling Slave Cylinder........................................................................................... 54 2-2 Platform Rotator........................................................................................................... 55 Jib Boom Components, Z-45/25J...................................................................................................... 57 3-1 Jib Boom................................................................................................................... 57 3-2 Jib Boom Lift Cylinder..................................................................................................... 58 Primary Boom Components............................................................................................................ 60 4-1 Cable Track................................................................................................................ 60 4-2 Primary Boom............................................................................................................... 64 4-3 Primary Boom Lift Cylinder................................................................................................. 67 4-4 Primary Boom Extension Cylinder............................................................................................ 68 4-5 Platform Leveling Master Cylinder.......................................................................................... 69 Secondary Boom Components.......................................................................................................... 70 5-1 Secondary Boom............................................................................................................. 71 5-2 Secondary Boom Lift Cylinders.............................................................................................. 76 Hydraulic Pumps.................................................................................................................... 77 6-1 Auxiliary Pump............................................................................................................. 77 6-2 Function Pump.............................................................................................................. 77 Manifolds.......................................................................................................................... 78 7-1 Function Manifold Components (before serial number 17841).................................................................. 78 7-2 Function Manifold Components (from serial number 17841 to 20379)........................................................... 82 7-3 Function Manifold Components (from serial number 20380 to 22565)........................................................... 84 7-4 Function Manifold Components (from serial number 22566 to 23235)........................................................... 86 7-5 Valve Adjustments - Function Manifold...................................................................................... 88 7-6 Jib Boom / Platform Rotate Manifold Components............................................................................. 90 7-7 Turntable Rotation Manifold Components..................................................................................... 91 Turntable Rotation Components...................................................................................................... 92 8-1 Rotation Hydraulic Motor (before serial number 18367)...................................................................... 92 8-2 Turntable Rotation Assembly (from serial number 18367 to 23235)............................................................ 94 Motor Controller................................................................................................................... 95 9-1 Motor Controller........................................................................................................... 95 Fault Codes............................................................................................................................ 97 Fault Code Chart................................................................................................................... 99 Schematics.............................................................................................................................103 Electrical Symbols Legend..........................................................................................................104 Hydraulic Symbols Legend...........................................................................................................105 Power Cable Diagram (before serial number 16839)...................................................................................108 Power Cable Diagram (from serial number 16840 to 21179)............................................................................109 Power Cable Diagram (from serial number 21180 to 22050)............................................................................112 Power Cable Diagram (from serial number 22051 to 23235)............................................................................113 Electrical Schematic, Z-45/25 (before serial number 13361).........................................................................116 Electrical Schematic, Z-45/25 (from serial number 13361 to 14078)..................................................................120 Electrical Schematic, Z-45/25 (from serial number 14079 to 14650)..................................................................124 Electrical Schematic, Z-45/25 (from serial number 14651 to 16839)..................................................................128 Electrical Schematic, Z-45/25 (from serial number 16840 to 17974)..................................................................132 Electrical Schematic, Z-45/25 (from serial number 17975 to 21180)..................................................................136 Electrical Schematic, Z-45/25 (from serial number 21180 to 22050)..................................................................140 Electrical Schematic, Z-45/25, ANSI and CSA Models (from serial number 22051 to 23235).............................................144 Electrical Schematic, Z-45/25, CE Models (from serial number 22051 to 23235).......................................................148 Electrical Schematic, Z-45/25J (before serial number 13361)........................................................................152 Electrical Schematic, Z-45/25J (from serial number 13361 to 14078).................................................................156 Electrical Schematic, Z-45/25J (from serial number 14079 to 14650).................................................................160 Electrical Schematic, Z-45/25J (from serial number 14651 to 16839).................................................................164 Electrical Schematic, Z-45/25J (from serial number 16840 to 17974).................................................................168 Electrical Schematic, Z-45/25J (from serial number 17975 to 21180).................................................................172 Electrical Schematic, Z-45/25J (from serial number 21180 to 22050).................................................................176 Electrical Schematic, Z-45/25J, ANSI and CSA Models (from serial number 22051 to 23235)............................................180 Electrical Schematic, Z-45/25J, CE Models (from serial number 22051 to 23235)......................................................184 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25 (before serial number 13361).............................................188 Ground Control Box Switch Panel Wiring Diagram, Z-45/25 (before serial number 13361)...............................................189 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25 (from serial number 13361 to 14078)......................................192 Ground Control Box Switch Panel Wiring Diagram, Z-45/25 (from serial number 13361 to 14078)........................................193 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25 (from serial number 14079 to 14650)......................................196 Ground Control Box Switch Panel Wiring Diagram, Z-45/25 (from serial number 14079 to 14650)........................................197 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25 (from serial number 14651 to 16839)......................................200 Ground Control Box Switch Panel Wiring Diagram, Z-45/25 (from serial number 14651 to 16839)........................................201 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25 (from serial number 16840 to 17974)......................................204 Ground Control Box Switch Panel Wiring Diagram, Z-45/25 (from serial number 16840 to 17974)........................................205 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25 (from serial number 17975 to 21180)......................................208 Ground Control Box Switch Panel Wiring Diagram, Z-45/25 (from serial number 17975 to 21180)........................................209 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25 (from serial number 21181 to 22050)......................................212 Ground Control Box Switch Panel Wiring Diagram, Z-45/25 (from serial number 21181 to 22050)........................................213 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25, ANSI and CSA Models (from serial number 22051 to 23235).................216 Ground Control Box Switch Panel Wiring Diagram, Z-45/25, ANSI and CSA Models (from serial number 22051 to 23235)...................217 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25, CE Models (from serial number 22051 to 23235)...........................220 Ground Control Box Switch Panel Wiring Diagram, Z-45/25, CE Models (from serial number 22051 to 23235).............................221 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J (before serial number 13361)............................................224 Ground Control Box Switch Panel Wiring Diagram, Z-45/25J (before serial number 13361)..............................................225 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J (from serial number 13361 to 14078).....................................228 Ground Control Box Switch Panel Wiring Diagram, Z-45/25J (from serial number 13361 to 14078).......................................229 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J (from serial number 14079 to 14650).....................................232 Ground Control Box Switch Panel Wiring Diagram, Z-45/25J (from serial number 14079 to 14650).......................................233 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J (from serial number 14651 to 16839).....................................236 Ground Control Box Switch Panel Wiring Diagram, Z-45/25J (from serial number 14651 to 16839).......................................237 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J (from serial number 16840 to 17974).....................................240 Ground Control Box Switch Panel Wiring Diagram, Z-45/25J (from serial number 16840 to 17974).......................................241 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J (from serial number 17975 to 21180).....................................244 Ground Control Box Switch Panel Wiring Diagram, Z-45/25J (from serial number 17975 to 21180).......................................245 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J (from serial number 21181 to 22050).....................................248 Ground Control Box Switch Panel Wiring Diagram, Z-45/25J (from serial number 21181 to 22050).......................................249 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J, ANSI and CSA Models (from serial number 22051 to 23235)................252 Ground Control Box Switch Panel Wiring Diagram, Z-45/25J, ANSI and CSA Models (from serial number 22051 to 23235)..................253 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J, CE Models (from serial number 22051 to 23235)..........................256 Ground Control Box Switch Panel Wiring Diagram, Z-45/25J, CE Models (from serial number 22051 to 23235)............................257 Platform Control Box Wiring Diagram, Z-45/25 (before serial number 13361)..........................................................260 Platform Control Box Wiring Diagram, Z-45/25 (with Platform Load Sense and LVI/BCI Option) (before serial number 13361)............261 Platform Control Box Wiring Diagram, Z-45/25 (from serial number 13361 to 14078)...................................................264 Platform Control Box Wiring Diagram, Z-45/25 (with Platform Load Sense and LVI/BCI Option)(from serial number 13361 to 14078)......265 Platform Control Box Wiring Diagram, Z-45/25 (from serial number 14079 to 14650)...................................................268 Platform Control Box Wiring Diagram, Z-45/25 (with Platform Load Sense and LVI/BCI Option)(from serial number 14079 to 14650)......269 Platform Control Box Wiring Diagram, Z-45/25 (from serial number 14651 to 16839)...................................................272 Platform Control Box Wiring Diagram, Z-45/25 with LVI/BCI Option (from serial number 14651 to 16839)...............................273 Platform Control Box Wiring Diagram, Z-45/25 (from serial number 16840 to 17974)...................................................276 Platform Control Box Wiring Diagram, Z-45/25 with LVI/BCI Option (from serial number 16840 to 17974)...............................277 Platform Control Box Wiring Diagram, Z-45/25 (from serial number 17975 to 21180)...................................................280 Platform Control Box Wiring Diagram, Z-45/25 with LVI/BCI Option (from serial number 17975 to 21180)...............................281 Platform Control Box Wiring Diagram, Z-45/25 (from serial number 21181 to 22050)...................................................284 Platform Control Box Wiring Diagram, Z-45/25 with LVI/BCI Option (from serial number 21181 to 22050)...............................285 Platform Control Box Wiring Diagram, Z-45/25 (from serial number 22051 to 23235)...................................................288 Platform Control Box Wiring Diagram, Z-45/25 with LVI/BCI Option (from serial number 22051 to 23235)...............................289 Platform Control Box Wiring Diagram, Z-45/25J (before serial number 13361).........................................................292 Platform Control Box Wiring Diagram, Z-45/25J (with Platform Load Sense and LVI/BCI Option) (before serial number 13361)...........293 Platform Control Box Wiring Diagram, Z-45/25J (from serial number 13361 to 14078)..................................................296 Platform Control Box Wiring Diagram, Z-45/25J (with Platform Load Sense and LVI/BCI Option) (from serial number 13361 to 14078)....297 Platform Control Box Wiring Diagram, Z-45/25J (from serial number 14079 to 14650)..................................................300 Platform Control Box Wiring Diagram, Z-45/25J (with Platform Load Sense and LVI/BCI Option) (from serial number 14079 to 14650)....301 Platform Control Box Wiring Diagram, Z-45/25J (from serial number 14651 to 16839)..................................................304 Platform Control Box Wiring Diagram, Z-45/25J with LVI/BCI Option (from serial number 14651 to 16839)..............................305 Platform Control Box Wiring Diagram, Z-45/25J (from serial number 16840 to 17974)..................................................308 Platform Control Box Wiring Diagram, Z-45/25J with LVI/BCI Option (from serial number 16840 to 17974)..............................309 Platform Control Box Wiring Diagram, Z-45/25J (from serial number 17975 to 21180)..................................................312 Platform Control Box Wiring Diagram, Z-45/25J with LVI/BCI Option (from serial number 17975 to 21180)..............................313 Platform Control Box Wiring Diagram, Z-45/25J (from serial number 21181 to 22050)..................................................316 Platform Control Box Wiring Diagram, Z-45/25J with LVI/BCI Option (from serial number 21181 to 22050)..............................317 Platform Control Box Wiring Diagram, Z-45/25J (from serial number 22051 to 23235)..................................................320 Platform Control Box Wiring Diagram, Z-45/25J with LVI/BCI Option (from serial number 22051 to 23235)..............................321 Hydraulic Schematic (before serial number 16962)...................................................................................324 Hydraulic Schematic (from serial number 16962 to 20379)............................................................................325 Hydraulic Schematic (from serial number 20380 to 22565)............................................................................328 Hydraulic Schematic (from serial number 22566 to 23235)............................................................................329 Back Cover.............................................................................................................................331
S.S 05/24
