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Genie Z-45/25 Z-45/25J DC Power Service Manual 107939 – PDF DOWNLOAD
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Genie Z-45/25 Z-45/25J DC Power Service Manual 107939 – PDF DOWNLOAD
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Description
Genie Z-45/25 Z-45/25J DC Power Service Manual 107939 – PDF DOWNLOAD
Language : English
Pages : 175
Downloadable : Yes
File Type : PDF
Table of Contents:
Genie Z-45/25 Z-45/25J DC Power Service Manual 107939 – PDF DOWNLOAD
Front Cover............................................................................................................................ 1 Introduction........................................................................................................................... 2 Revision History ...................................................................................................................... 3 Serial Number Legend................................................................................................................... 5 Safety Rules........................................................................................................................... 7 Table of Contents...................................................................................................................... 9 Specifications......................................................................................................................... 15 Machine Specifications............................................................................................................. 15 Performance Specifications......................................................................................................... 16 Hydraulic Specifications........................................................................................................... 17 Manifold Component Specifications.................................................................................................. 18 Machine Torque Specifications...................................................................................................... 18 Hydraulic Hose and Fitting Torque Specifications................................................................................... 19 SAE and Metric Fastener Torque Charts.............................................................................................. 20 Scheduled Maintenance Procedures....................................................................................................... 21 Pre-Delivery Preparation........................................................................................................... 23 Maintenance Inspection Report...................................................................................................... 25 Checklist A Procedures............................................................................................................. 0 A-1 Inspect the Manuals and Decals............................................................................................. 27 A-2 Perform Pre-operation Inspection........................................................................................... 28 A-3 Perform Function Tests..................................................................................................... 28 A-4 Perform 30 Day Service..................................................................................................... 29 A-5 Grease the Turntable Rotation Bearing and Rotate Gear...................................................................... 29 A-6 Replace the Drive Hub Oil.................................................................................................. 30 Checklist B Procedures............................................................................................................. 0 B-1 Check the Batteries........................................................................................................ 31 B-2 Inspect the Electrical Wiring.............................................................................................. 32 B-3 Test the Key Switch........................................................................................................ 33 B-4 Check the Tires, Wheels and Lug Nut Torque................................................................................. 34 B-5 Confirm the Proper Brake Configuration..................................................................................... 34 B-6 Check the Oil Level in the Drive Hubs and Mounting Bolt Torque............................................................. 35 B-7 Test the Ground Control Override........................................................................................... 36 B-8 Test the Platform Self-leveling............................................................................................ 36 B-9 Test the Drive Brakes...................................................................................................... 37 B-10 Test the Drive Speed - Stowed Position.................................................................................... 37 B-11 Test the Drive Speed - Raised or Extended Position........................................................................ 38 B-12 Test the Alarm Package (if equipped)...................................................................................... 38 B-13 Test the Turntable Rotation Stop.......................................................................................... 39 B-14 Check the Electrical Contactors........................................................................................... 40 B-15 Perform Hydraulic Oil Analysis............................................................................................ 40 B-16 Test the Emergency Power System .......................................................................................... 41 Checklist C Procedures............................................................................................................. 0 C-1 Grease the Platform Overload Mechanism (if equipped)....................................................................... 42 C-2 Test the Platform Overload Sytem (if equipped)............................................................................. 43 Checklist D Procedures............................................................................................................. 0 D-1 Check the Primary Boom Wear Pads........................................................................................... 46 D-2 Check the Turntable Rotation Bearing Bolts................................................................................. 46 D-3 Check the Free-wheel Configuration......................................................................................... 48 D-4 Replace the Drive Hub oil.................................................................................................. 49 D-5 Replace the Hydraulic Tank Return Filter Element........................................................................... 50 D-6 Inspect for Turntable Bearing Wear......................................................................................... 50 Checklist E Procedures............................................................................................................. 0 E-1 Test or Replace the Hydraulic Oil.......................................................................................... 52 E-2 Grease the Steer Axle Wheel Bearings....................................................................................... 53 Repair Procedures...................................................................................................................... 55 Platform Controls.................................................................................................................. 56 1-1 Controllers................................................................................................................ 56 Platform Components................................................................................................................ 58 2-1 Platform Leveling Slave Cylinder........................................................................................... 58 2-2 Platform Rotator........................................................................................................... 60 2-3 Platform Overload system (if equipped)..................................................................................... 62 Jib Boom Components, Z-45/25J...................................................................................................... 64 3-1 Jib Boom................................................................................................................... 64 3-2 Jib Boom Lift Cylinder..................................................................................................... 66 Primary Boom Components............................................................................................................ 67 4-1 Cable Track................................................................................................................ 67 4-2 Primary Boom............................................................................................................... 71 4-3 Primary Boom Lift Cylinder................................................................................................. 74 4-4 Primary Boom Extension Cylinder............................................................................................ 75 4-5 Platform Leveling Master Cylinder.......................................................................................... 76 Secondary Boom Components.......................................................................................................... 77 5-1 Secondary Boom............................................................................................................. 78 5-2 Secondary Boom Lift Cylinders.............................................................................................. 82 Hydraulic Pumps.................................................................................................................... 83 6-1 Auxiliary and Function Pump................................................................................................ 83 Manifolds.......................................................................................................................... 84 7-1 Function Manifold Components............................................................................................... 84 7-2 Valve Adjustments - Function Manifold...................................................................................... 86 7-3 Jib Boom / Platform Rotate Manifold Components............................................................................. 87 7-4 Turntable Rotation Manifold Components..................................................................................... 88 7-5 Valve Coils................................................................................................................ 89 Turntable Rotation Components...................................................................................................... 91 8-1 Turntable Rotation Assembly................................................................................................ 91 Motor Controller................................................................................................................... 92 9-1 Motor Controller........................................................................................................... 92 Fault Codes............................................................................................................................ 93 Fault Code Chart................................................................................................................... 95 Schematics............................................................................................................................. 99 Electrical Symbols Legend..........................................................................................................100 Hydraulic Symbols Legend...........................................................................................................101 Electrical Schematics before serial number 31015...................................................................................101 Electrical Schematic, Z-45/25 and Z-45/25J, ANSI • CSA • AS (before serial number 31015).......................................104 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25 and Z-45/25J, ANSI • CSA • AS (before serial number 31015)...........108 Ground Control Box Switch Panel Wiring Diagram, Z-45/25 and Z-45/25J, ANSI • CSA • AS (before serial number 31015).............109 Platform Control Box Wiring diagram, Z-45/25 and Z-45/25J, ANSI • CSA • AS (before serial number 31015)........................111 Electrical Schematic, Z-45/25 and Z-45/25J, CE (before serial number 31015)....................................................114 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25 and Z-45/25J, CE (before serial number 31015)........................118 Ground Control Box Switch Panel Wiring Diagram, Z-45/25 and Z-45/25J, CE (before serial number 31015)..........................119 Platform Control Box Wiring Diagram, Z-45/25 and Z-45/25J, CE (before serial number 31015).....................................121 Electrical Schematics from serial number 31015 to 39313............................................................................101 Electrical Schematic, Z-45/25 and Z-45/25J, ANSI • CSA • AS (from serial number 31015 to 39313)................................124 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25 and Z-45/25J, ANSI • CSA • AS (from serial number 31015 to 39313)....128 Ground Control Box Switch Panel Wiring Diagram, Z-45/25 and Z-45/25J, ANSI • CSA • AS (from serial number 31015 to 39313)......129 Platform Control Box Wiring Diagram, Z-45/25 and Z-45/25J, ANSI • CSA • AS (from serial number 31015 to 39313).................131 Electrical Schematic, Z-45/25 and Z-45/25J, CE (from serial number 31015 to 39313).............................................134 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25 and Z-45/25J, CE (from serial number 31015 to 39313).................138 Ground Control Box Switch Panel Wiring Diagram, Z-45/25 and Z-45/25J, CE (from serial number 31015 to 39313)...................139 Platform Control Box Wiring Diagram, Z-45/25 and Z-45/25J, CE (from serial number 31015 to 39313)..............................141 Electrical Schematics after serial number 39313....................................................................................144 Electrical Schematic, Z-45/25 and Z-45/25J, ANSI • CSA • AS (after serial number 39313)........................................144 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25 and Z-45/25J, ANSI • CSA • AS (after serial number 39313)............148 Ground Control Box Switch Panel Wiring Diagram, Z-45/25 and Z-45/25J, ANSI • CSA • AS (after serial number 39313)..............149 Platform Control Box Wiring Diagram, Z-45/25 and Z-45/25J, ANSI • CSA • AS (after serial number 39313).........................151 Electrical Schematic, Z-45/25 and Z-45/25J, CE (after serial number 39313).....................................................154 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25 and Z-45/25J, CE (after serial number 39313).........................158 Ground Control Box Switch Panel Wiring Diagram, Z-45/25 and Z-45/25J, CE (after serial number 39313)...........................159 Platform Control Box Wiring Diagram, Z-45/25 and Z-45/25J, CE (after serial number 39313)......................................162 Power Cable Wiring Diagram.........................................................................................................163 CTE Option, CE.....................................................................................................................166 Charger Interlock Option...........................................................................................................167 Platform Control Box LVI / BCI Option Wiring Diagram (before serial number 31015)..................................................170 Platform Control Box LVI / BCI Option Wiring Diagram (after serial number 31014)...................................................171 Hydraulic Schematic................................................................................................................173 Back Cover.............................................................................................................................175
S.S 04/24
