Genie Z-45/25 Z-45/25J Bi-Energy Power Service Manual 110188 – PDF DOWNLOAD
Language : English
Pages : 169
Downloadable : Yes
File Type : PDF
Table of Contents:
Genie Z-45/25 Z-45/25J Bi-Energy Power Service Manual 110188 – 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-E and Z482-E2B Engines................................................. 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..................................... 38 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........................................... 41 B-10 Test the Platform Self-leveling........................................... 42 B-11 Test the Engine Idle Select............................................... 42 B-12 Test the Drive Brakes..................................................... 43 B-13 Test the Drive Speed - Stowed Position.................................... 43 B-14 Test the Drive Speed - Raised or Extended Position........................ 44 B-15 Test the Alarm Package (if equipped)...................................... 44 B-16 Check the Electrical Contactors........................................... 45 B-17 Perform Hydraulic Oil Analysis............................................ 46 B-18 Perform Engine Maintenance................................................ 46 Checklist C Procedures............................................................. 47 C-1 Perform Engine Maintenance................................................. 47 C-2 Grease the Platform Overload Mechanism (if equipped)....................... 47 C-3 Test the Platform Overload System (if equipped)............................ 48 C-4 Perform Engine Maintenance................................................. 50 Checklist D Procedures............................................................. 51 D-1 Check the Primary Boom Wear Pads........................................... 51 D-2 Check the Free-wheel Configuration......................................... 51 D-3 Replace the Drive Hub Oil.................................................. 52 D-4 Replace the Hydraulic Tank Return Filter................................... 53 D-5 Calibrate the Platform Overload System (if equipped)....................... 54 D-6 Check the Turntable Rotation Bearing Bolts................................. 56 D-7 Inspect for Turntable Bearing Wear......................................... 57 D-8 Perform Engine Maintenance................................................. 59 D-9 Perform Engine Maintenance................................................. 59 Checklist E Procedures............................................................. 60 E-1 Test or Replace the Hydraulic Oil.......................................... 60 E-2 Grease the Steer Axle Wheel Bearings....................................... 61 E-3 Perform Engine Maintenance................................................. 63 E-4 Perform Engine Maintenance, Z4822-E2B Engine............................... 63 Repair Procedures...................................................................... 65 Platform Controls.................................................................. 66 1-1 Controllers................................................................ 66 Platform Components................................................................ 68 2-1 Platform Leveling Slave Cylinder........................................... 68 2-2 Platform Rotator........................................................... 69 Jib Boom Components, Z-45/25J...................................................... 71 3-1 Jib Boom................................................................... 71 3-2 Jib Boom Lift Cylinder..................................................... 72 Primary Boom Components............................................................ 74 4-1 Cable Track................................................................ 74 4-2 Primary Boom............................................................... 78 4-3 Primary Boom Lift Cylinder................................................. 81 4-4 Primary Boom Extension Cylinder............................................ 82 4-5 Platform Leveling Master Cylinder.......................................... 83 Secondary Boom Components.......................................................... 84 5-1 Secondary Boom............................................................. 85 5-2 Secondary Boom Lift Cylinders.............................................. 90 Kubota Z482-E Engine............................................................... 91 6-1 Timing Adjustment.......................................................... 91 6-2 RPM Adjustment............................................................. 91 6-3 Engine Drive Pulley........................................................ 91 Generator.......................................................................... 93 7-1 Generator Pulley........................................................... 93 7-2 Generator Belts............................................................ 94 7-3 Generator Voltage Regulator................................................ 94 Hydraulic Pumps.................................................................... 97 8-1 Auxiliary Pump............................................................. 97 8-2 Function Pump.............................................................. 98 Manifolds..........................................................................100 9-1 Function Manifold Components...............................................100 9-2 Valve Adjustments - Function Manifold......................................102 9-3 Jib Boom / Platform Rotate Manifold Components.............................103 9-4 Turntable Rotation Manifold Components.....................................104 9-5 Valve Coils................................................................105 Turntable Rotation Components......................................................107 10-1 Turntable Rotation Assembly...............................................107 Motor Controller...................................................................109 11-1 Motor Controller..........................................................109 Fault Codes............................................................................111 Fault Code Chart...................................................................113 Schematics.............................................................................117 Electrical Symbols Legend..........................................................118 Hydraulic Symbols Legend...........................................................119 Power Cable Diagram................................................................122 Engine Panel Diagram...............................................................123 Electrical Schematic, Z-45/25, ANSI and CSA Models.................................126 Electrical Schematic, Z-45/25, CE Models...........................................130 Electrical Schematic, Z-45/25J, ANSI and CSA Models................................134 Electrical Schematic, Z-45/25J, CE Models..........................................138 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25, ANSI and CSA Models.....142 Ground Control Box Switch Panel Wiring Diagram, Z-45/25, ANSI and CSA Models.......143 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25, CE Models...............146 Ground Control Box Switch Panel Wiring Diagram, Z-45/25, CE Models.................147 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J, ANSI and CSA Models....150 Ground Control Box Switch Panel Wiring Diagram, Z-45/25J, ANSI and CSA Models......151 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J, CE Models..............154 Ground Control Box Switch Panel Wiring Diagram, Z-45/25J, CE Models................155 Platform Control Box Wiring Diagram, Z-45/25.......................................158 Platform Control Box Wiring Diagram, Z-45/25 with LVI/BCI Option...................159 Platform Control Box Wiring Diagram, Z-45/25J......................................162 Platform Control Box Wiring Diagram, Z-45/25J with LVI/BCI Option..................163 Platform Level Cutout, CTE Option..................................................166 Hydraulic Schematic................................................................167 Back Cover.............................................................................169
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