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Genie Z-62/40 Service & Repair Manual 1268555 – PDF DOWNLOAD
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Description
Genie Z-62/40 Service & Repair Manual 1268555 – PDF DOWNLOAD
Language : English
Pages : 287
Downloadable : Yes
File Type : PDF
Table of Contents:
Genie Z-62/40 Service & Repair Manual 1268555 – PDF DOWNLOAD
Front Cover....................................................................................................... 1 Important Information............................................................................................. 2 Find a Manual for this Model...................................................................................... 2 Revision History.................................................................................................. 3 Serial Number Legend.............................................................................................. 4 General Safety Rules.............................................................................................. 5 Table of Contents................................................................................................. 7 Specifications.................................................................................................... 15 Machine Specifications........................................................................................ 15 Performance Specifications.................................................................................... 16 Hydraulic Oil Specifications.................................................................................. 16 Hydraulic Component Specifications............................................................................ 19 Manifold Component Specifications............................................................................. 20 Ford MSG-425 EFI Engine Specifications........................................................................ 21 Deutz D2011 L03i Engine Specifications........................................................................ 22 Deutz TD2011 L04i Engine Specifications....................................................................... 23 Deutz TD 2.2 L3 Engine Specifications......................................................................... 24 Deutz D 2.9 L4 Engine Specifications.......................................................................... 25 Perkins 404D-22 Engine Specifications......................................................................... 26 Perkins 404F-22 Engine Specifications......................................................................... 27 Machine Torque Specifications................................................................................. 28 TRAX Torque Specifications.................................................................................... 28 Hydraulic Hose and Fitting Torque Specifications.............................................................. 29 Torque Procedure.............................................................................................. 30 SAE and Metric Fasteners Torque Charts........................................................................ 32 Repair Procedures................................................................................................. 33 Introduction.................................................................................................. 33 Platform Controls............................................................................................. 35 1-1 ALC-500 Circuit Board................................................................................. 35 1-2 Joysticks............................................................................................. 36 How to Adjust the Joystick Threshold Setting.......................................................... 36 How to Adjust the Joystick Max-out Setting............................................................ 37 How to Adjust the Joystick Ramp Rate Setting.......................................................... 38 Platform Components........................................................................................... 40 2-1 Platform Leveling Slave Cylinder...................................................................... 40 2-2 Platform Rotator...................................................................................... 42 2-3 Platform Overload System.............................................................................. 44 Jib Boom Components........................................................................................... 46 3-1 Jib Boom.............................................................................................. 46 3-2 Jib Boom Lift Cylinder................................................................................ 47 Primary Boom Components....................................................................................... 48 4-1 Cable Track........................................................................................... 48 How to Remove the Cable Track......................................................................... 48 How to Repair the Cable Track......................................................................... 49 4-2 Primary Boom.......................................................................................... 49 How to Disassemble the Primary Boom................................................................... 50 4-3 Primary Boom Lift Cylinder............................................................................ 51 4-4 Primary Boom Extension Cylinder....................................................................... 52 4-5 Platform Leveling Master Cylinder..................................................................... 53 Secondary Boom Components..................................................................................... 54 5-1 Secondary Boom Lift Cylinder.......................................................................... 55 Engines....................................................................................................... 57 6-1 RPM adjustment - Deutz Models......................................................................... 57 6-2 RPM adjustment - Perkins Models....................................................................... 57 6-3 Flex Plate............................................................................................ 57 How to Install the Flex Plate......................................................................... 58 How to install the Pump and Bell Housing Assembly..................................................... 60 6-4 Ford MSG-425 Engine Fault Codes....................................................................... 61 6-5 Engine Fault Codes - Deutz TD 2.2 L3 Models........................................................... 62 6-6 Engine Fault Codes - Deutz D 2.9 L4 and Perkins 404F-22 Models........................................ 62 6-7 Diesel Particle Filter Regeneration - Deutz TD 2.2 L3................................................. 63 Hydraulic Pumps............................................................................................... 64 7-1 Function Pump......................................................................................... 64 7-2 Drive Pump............................................................................................ 65 Manifolds..................................................................................................... 68 8-1 Function Manifold Components.......................................................................... 68 8-2 Valve Adjustments - Function Manifold................................................................. 74 How to Adjust the System Relief Valve................................................................. 74 How to Adjust the Platform Level Up Relief Valve...................................................... 74 How to Adjust the Platform Level Down Relief Valve.................................................... 75 8-3 Jib Boom / Platform Rotate Manifold Components........................................................ 76 8-4 Brake / Two Speed Manifold Components................................................................. 77 8-5 Brake / Two Speed / Steer Mode Manifold Components.................................................... 78 8-6 Steer Select Manifold Components...................................................................... 79 8-7 Turntable Rotation Manifold Components................................................................ 80 8-8 Oscillate Directional Valve Manifold Components....................................................... 81 8-9 How to Set Up the Oscillate Directional Valve......................................................... 82 8-10 Valve Adjustment - Oscillate Relief Valve............................................................ 83 8-11 Drive Oil Diverter Manifold Components (welder option)............................................... 84 8-12 Traction Manifold Components, 2WD.................................................................... 86 8-13 Traction Manifold Components, 4WD.................................................................... 88 8-14 Valve Adjustments, Traction Manifold................................................................. 90 8-15 Hydraulic Generator Manifold Components, 3kW......................................................... 91 8-16 Valve Coils.......................................................................................... 92 How to Test a Coil Diode.............................................................................. 93 Turntable Rotation Components................................................................................. 94 9-1 Turntable Rotation Assembly........................................................................... 94 Axle Components............................................................................................... 96 10-1 Oscillating Axle Cylinders........................................................................... 96 Track Components.............................................................................................. 97 11-1 Track Assembly....................................................................................... 97 Generators....................................................................................................101 12-1 Hydraulic Generator..................................................................................101 Fault Codes.......................................................................................................102 Introduction..................................................................................................102 Control System Fault Codes....................................................................................103 How to Retrieve Control System Fault Codes................................................................103 Control System Fault Codes................................................................................104 Fault Code Display - Deutz and Perkins Models.................................................................107 How to Retrieve Active Engine Fault Codes Deutz D 2.9 L4 and Perkins 404F-22 Models.......................107 How to Retrieve Active Engine Fault Codes - Deutz TD 2.2 L3 Models........................................108 Fault Code Display - Flashing and Solid LED's - Deutz D 2.9 L4 and Perkins 404F-22 Models.................109 Soft Key Functions and Icons - Deutz D 2.9 L4 and Perkins 404F-22 Models..................................110 Soft Key Functions and Icons - Deutz TD 2.2 L3 Models.....................................................111 Main Menu Structure - Deutz D 2.9 L4 Models...............................................................112 Main Menu Structure - Deutz TD 2.2 L3 Models..............................................................113 Main Menu Structure - Perkins 404F-22 Models..............................................................114 Deutz TD 2.2 L3 Engine Fault Codes............................................................................115 Deutz D 2.9 L4 Engine Fault Codes.............................................................................125 Perkins 404F-E22T Engine Fault Codes..........................................................................136 Ford MSG-425 Engine Fault Codes...............................................................................138 How to Retrieve Ford MSG-425 Engine Fault Codes...........................................................138 Schematics........................................................................................................144 Introduction..................................................................................................144 Electrical Symbol Legend......................................................................................145 Hydraulic Symbols Legend......................................................................................146 Electrical Component and Wire Color Legends...................................................................147 Ford Engine Relay Layout......................................................................................151 Engine Relay Layout - Deutz TD 2.2 L3, D 2.9 L4 and Perkins 404F-22...........................................152 Limit Switch Legend...........................................................................................153 Electrical Schematics – Options...............................................................................155 Ford MSG-425 EFI Engine Wire Harness......................................................................156 Deutz D 2.9 L4 Engine Wire Harness........................................................................157 Deutz TD 2.2 L3 Engine Wire Harness.......................................................................160 Electrical Schematic, Options (All Models)................................................................161 Perkins 404F-22 Engine Wire Harness.......................................................................164 Electrical Schematic, Options (All Models)................................................................165 Wiring Diagram, 3kW Hydraulic Generator...................................................................168 Wiring Diagram, 12kW Hydraulic Generator - Welder Option..................................................169 Hydraulic Schematic, 12kw Hydraulic Generator - Welder Option.............................................171 Wiring Diagram, Lift / Drive Option.......................................................................174 Wiring Diagram, Platform Overload Option..................................................................175 Wiring Diagram, Platform Overload and Lift / Drive Option.................................................178 Wiring Diagram, Work Lights Option........................................................................179 Wiring Diagram, Aircraft Protection Option................................................................182 Wiring Diagram, Platform Control Box Heater Option........................................................183 Wiring Diagram, Fuel Level Sensing Option.................................................................185 Hydraulic Schematics..........................................................................................187 Hydraulic Schematic, 2WD - 2 Wheel Steer Models [to serial numbers Z62D-546, Z62H-4484, from Z62M-101]....188 Hydraulic Schematic, 2WD - 2 Wheel Steer Models [from serial numbers Z62D-547, Z62H-4485].................189 Hydraulic Schematic, 4WD - 2 Wheel Steer Models [to serial numbers Z62D-546, Z62H-4484, from Z62M-101]....192 Hydraulic Schematic, 4WD - 2 Wheel Steer Models [from serial numbers Z62D-547, Z62H-4485].................193 Hydraulic Schematic, 4WD - 4 Wheel Steer Models [to serial numbers Z62D-546, Z62H-4484, from Z62M-101]....196 Hydraulic Schematic, 4WD - 4 Wheel Steer Models [from serial numbers Z62D-547, Z62H-4485].................197 Electrical Schematics – ANSI and CSA Models...................................................................199 Electrical Schematic, Ford MSG-425 EFI Models (ANSI/CSA)..................................................200 Ground Control Box Terminal Strip Wiring Diagram, Ford MSG-425 EFI Models (ANSI/CSA)......................204 Ground Control Box Switch Panel Wiring Diagram, Ford MSG-425 EFI Models (ANSI/CSA)........................205 Platform Control Box Wiring Diagram, Ford MSG-425 EFI Models (ANSI/CSA)...................................208 Platform Control Box Switch Panel Wiring Diagram, Ford MSG-425 EFI Models (ANSI/CSA)......................209 Electrical Schematic, Deutz D2011 L03i / Perkins 404D-22 Models (ANSI/CSA)................................212 Ground Control Box Terminal Strip Wiring Diagram, Deutz D2011 L03i / Perkins 404D-22 Models (ANSI/CSA)....216 Ground Control Box Switch Panel Wiring Diagram, Deutz D2011 L03i / Perkins 404D-22 Models (ANSI/CSA)......217 Platform Control Box Wiring Diagram, Deutz D2011 L03i / Perkins 404D-22 Models (ANSI/CSA).................220 Platform Control Box Switch Panel Wiring Diagram, Deutz D2011 L03i / Perkins 404D-22 Models (ANSI/CSA)....221 Electrical Schematic, Deutz D 2.9 L4 Models (ANSI/CSA)....................................................224 Ground Control Box Terminal Strip Wiring Diagram, Deutz D 2.9 L4 Models (ANSI/CSA)........................228 Ground Control Box Switch Panel Wiring Diagram, Deutz D 2.9 L4 Models (ANSI/CSA)..........................229 Platform Control Box Wiring Diagram, Deutz D 2.9 L4 Models (ANSI/CSA).....................................232 Platform Control Box Switch Panel Wiring Diagram, Deutz D 2.9 L4 Models (ANSI/CSA)........................233 Electrical Schematic, Perkins 404F-22 Models (ANSI/CSA)...................................................236 Ground Control Box Terminal Strip Wiring Diagram, Perkins 404F-22 Models (ANSI/CSA).......................240 Ground Control Box Switch Panel Wiring Diagram, Perkins 404F-22 Models (ANSI/CSA).........................241 Platform Control Box Wiring Diagram, Perkins 404F-22 Models (ANSI/CSA)....................................244 Platform Control Box Switch Panel Wiring Diagram, Perkins 404F-22 Models (ANSI/CSA).......................245 Electrical Schematic, Perkins 404F-22 Models (ANSI/CSA)...................................................248 Ground Control Box Terminal Strip Wiring Diagram, Perkins 404F-22 Models (ANSI/CSA).......................252 Ground Control Box Switch Panel Wiring Diagram, Perkins 404F-22 Models (ANSI/CSA).........................253 Platform Control Box Wiring Diagram, Perkins 404F-22 Models (ANSI/CSA)....................................256 Platform Control Box Switch Panel Wiring Diagram, Perkins 404F-22 Models (ANSI/CSA).......................257 Electrical Schematics – AS and CE Models......................................................................259 Electrical Schematic, Ford MSG-425 EFI Models (AS/CE).....................................................260 Ground Control Box Terminal Strip Wiring Diagram, Ford MSG-425 EFI Models (AS/CE).........................264 Ground Control Box Switch Panel Wiring Diagram, Ford MSG-425 EFI Models (AS/CE)...........................265 Platform Control Box Wiring Diagram, Ford MSG-425 EFI Models (AS/CE)......................................268 Platform Control Box Switch Panel Wiring Diagram, Ford MSG-425 EFI Models (AS/CE).........................269 Electrical Schematic, Deutz 2011 L03i / Perkins 404D-22 Models (AS/CE)....................................272 Ground Control Box Terminal Strip Wiring Diagram, Deutz 2011 L03i / Perkins 404D-22 Models (AS/CE)........276 Ground Control Box Switch Panel Wiring Diagram, Deutz 2011 L03i / Perkins 404D-22 Models (AS/CE)..........277 Platform Control Box Wiring Diagram, Deutz 2011 L03i / Perkins 404D-22 Models (AS/CE).....................280 Platform Control Box Switch Panel Wiring Diagram, Deutz 2011 L03i / Perkins 404D-22 Models (AS/CE)........281 Electrical Schematic, Deutz TD 2.2 L3 Models (CE).........................................................284 Back Cover........................................................................................................287
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