Genie Z-45/25 Manuale utente

ServiceManual

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PartNo.106488

RevA2

March2005

Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488

July 2004

Introduction

Important

Read, understand and obey the safety rules and

operating instructions in the

Genie Z-45/25

Bi-Energy and

Genie Z-45/25J Bi-Energy Operator's

Manual

before attempting any maintenance or

repair procedure.

This manual provides detailed scheduled

maintenance information for the machine owner and

user. It also provides troubleshooting fault codes

and repair procedures for qualified service

professionals.

Basic mechanical, hydraulic and electrical skills are

required to perform most procedures. However,

several procedures require specialized skills, tools,

lifting equipment and a suitable workshop. In these

instances, we strongly recommend that

maintenance and repair be performed at an

authorized Genie dealer service center.

Technical Publications

Genie Industries has endeavored to deliver the

highest degree of accuracy possible. However,

continuous improvement of our products is a Genie

policy. Therefore, product specifications are subject

to change without notice.

Readers are encouraged to notify Genie of errors

and send in suggestions for improvement. All

communications will be carefully considered for

future printings of this and all other manuals.

http://www.genieindustries.com

e-mail: [email protected]

106488 Rev A July 2004

Second Edition, First Printing

"Genie" and "Z" are registered trademarks of

Genie Industries in the USA and many other

countries.

Printed on recycled paper

Printed in U.S.A.

Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy

July 2004

iii

Danger

Failure to obey the instructions and safety rules

in this manual and the

Genie Z-45/25 Bi-Energy and

Genie Z-45/25J Bi-Energy Operator’s Manual

will

result in death or serious injury.

Many of the hazards identified in the

operator’s manual are also safety hazards

when maintenance and repair procedures

are performed.

Do Not Perform Maintenance

Unless:

You are trained and qualified to perform

maintenance on this machine.

You read, understand and obey:

- manufacturer’s instructions and safety rules

- employer’s safety rules and worksite

regulations

- applicable governmental regulations

You have the appropriate tools, lifting

equipment and a suitable workshop.

Safety Rules

Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488

July 2004

SAFETY RULES

Personal Safety

Any person working on or around a machine must

be aware of all known safety hazards. Personal

safety and the continued safe operation of the

machine should be your top priority.

Read each procedure thoroughly. This

manual and the decals on the machine,

use signal words to identify the following:

Safety alert symbol—used to alert

personnel to potential personal

injury hazards. Obey all safety

messages that follow this symbol

to avoid possible injury or death.

Used to indicate the presence of

an imminently hazardous situation

which, if not avoided, will result in

death or serious injury.

Used to indicate the presence of a

potentially hazardous situation

which, if not avoided, could result

in death or serious injury.

With safety alert symbol—used to

indicate the presence of a

potentially hazardous situation

which, if not avoided, may cause

minor or moderate injury.

Without safety alert symbol—used

to indicate the presence of a

potentially hazardous situation

which, if not avoided, may result in

property damage.

Used to indicate operation or

maintenance information.

Be sure to wear protective eye wear and

other protective clothing if the situation

warrants it.

Be aware of potential crushing hazards

such as moving parts, free swinging or

unsecured components when lifting or

placing loads. Always wear approved steel-toed

shoes.

Workplace Safety

Be sure to keep sparks, flames and

lighted tobacco away from flammable and

combustible materials like battery gases

and engine fuels. Always have an approved fire

extinguisher within easy reach.

Be sure that all tools and working areas

are properly maintained and ready for use.

Keep work surfaces clean and free of

debris that could get into machine components and

cause damage.

Be sure that your workshop or work area is

properly ventilated and well lit.

Be sure any forklift, overhead crane or

other lifting or supporting device is fully

capable of supporting and stabilizing the

weight to be lifted. Use only chains or straps that

are in good condition and of ample capacity.

Be sure that fasteners intended for one

time use (i.e., cotter pins and self-locking

nuts) are not reused. These components

may fail if they are used a second time.

Be sure to properly dispose of old oil or

other fluids. Use an approved container.

Please be environmentally safe .

Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy

August 2004

Table of Contents

Introduction

Important Information ...................................................................................................

Section 1 Safety Rules

General Safety Rules ..................................................................................................

iii

Section 2 Rev Specifications

A Machine Specifications .......................................................................................... 2 - 1

A Performance Specifications ................................................................................... 2 - 2

A Hydraulic Specifications ........................................................................................ 2 - 3

A Manifold Component Specifications ....................................................................... 2 - 4

A Machine Torque Specifications .............................................................................. 2 - 4

A Kubota Z482-E Engine Specifications .................................................................... 2 - 5

A Generator ............................................................................................................... 2 - 6

A Generator Torque Specifications ............................................................................ 2 - 6

A Hydraulic Hose and Fitting Torque Specifications .................................................. 2 - 7

Section 3 Rev Scheduled Maintenance Procedures

Introduction ............................................................................................................ 3 - 1

Pre-delivery Preparation ......................................................................................... 3 - 3

Maintenance Inspection Report .............................................................................. 3 - 5

AChecklist A Procedures

A-1 Perform Pre-operation Inspection ................................................................. 3 - 7

A-2 Check for Fuel Leaks ................................................................................... 3 - 7

A-3 Check for Hydraulic Leaks ........................................................................... 3 - 8

Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488

August 2004

TABLE OF CONTENTS

Section 3 Rev Scheduled Maintenance Procedures,continued

A-4 Check the Generator Belts and Pulleys ........................................................ 3 - 8

A-5 Perform Function Tests .............................................................................. 3 - 10

A-6 Perform 30 Day Service ............................................................................. 3 - 10

A-7 Perform Engine Maintenance ..................................................................... 3 - 10

A-8 Perform Engine Maintenance ..................................................................... 3 - 11

A-9 Grease the Turntable Rotation Bearing and Rotate Gear ............................ 3 - 11

A-10 Perform Engine Maintenance ..................................................................... 3 - 12

A-11 Perform Engine Maintenance ..................................................................... 3 - 12

A-12 Perform Engine Maintenance ..................................................................... 3 - 13

AChecklist B Procedures

B-1 Check the Radiator ..................................................................................... 3 - 14

B-2 Check the Exhaust System ....................................................................... 3 - 14

B-3 Check the Batteries.................................................................................... 3 - 15

B-4 Inspect the Electrical Wiring ....................................................................... 3 - 16

B-5 Check the Lug Nut Torque (including the tires and wheels) ......................... 3 - 16

B-6 Confirm the Proper Brake Configuration...................................................... 3 - 17

B-7 Check the Oil Level in the Drive Hubs ........................................................ 3 - 17

B-8 Check and Adjust the Engine RPM ............................................................ 3 - 18

B-9 Test the Ground Control Override ............................................................... 3 - 19

B-10 Test the Platform Self-leveling ................................................................... 3 - 20

B-11 Test the Engine Idle Select ........................................................................ 3 - 20

B-12 Test the Drive Brakes ................................................................................ 3 - 21

B-13 Test the Drive Speed - Stowed Position ..................................................... 3 - 22

Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy

March 2005

TABLE OF CONTENTS

vii

Section 3 Rev Scheduled Maintenance Procedures,continued

B-14 Test the Drive Speed - Raised or Extended Position .................................. 3 - 22

B-15 Test the Alarm Package (if equipped) ........................................................ 3 - 23

B-16 Test the Turntable Rotation Stop ................................................................ 3 - 24

B-17 Check the Electrical Contactors ................................................................. 3 - 24

B-18 Replace the Hydraulic Tank Return Filter ................................................... 3 - 25

B-19 Perform Hydraulic Oil Analysis ................................................................... 3 - 25

B-20 Perform Engine Maintenance ..................................................................... 3 - 26

AChecklist C Procedures

C-1 Perform Engine Maintenance ..................................................................... 3 - 27

C-2 Grease the Platform Overload Mechanism (if equipped) ............................. 3 - 27

C-3 Test the Platform Overload Mechanism (if equipped) ................................. 3 - 28

C-4 Perform Engine Maintenance ..................................................................... 3 - 30

AChecklist D Procedures

D-1 Check the Primary Boom Wear Pads ......................................................... 3 - 31

D-2 Check the Turntable Rotation Bearing Bolts ............................................... 3 - 31

D-3 Check the Free-wheel Configuration ........................................................... 3 - 33

D-4 Replace the Drive Hub Oil .......................................................................... 3 - 34

D-5 Calibrate the Platform Overload System (if equipped) ................................ 3 - 34

D-6 Perform Engine Maintenance ..................................................................... 3 - 36

D-7 Perform Engine Maintenance ..................................................................... 3 - 36

AChecklist E Procedures

E-1 Test or Replace the Hydraulic Oil ............................................................... 3 - 37

E-2 Perform Engine Maintenance ..................................................................... 3 - 38

E-3 Grease the Steer Axle Wheel Bearings ...................................................... 3 - 39

Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488

August 2004

TABLE OF CONTENTS

viii

Section 4 Rev Repair Procedures

Introduction ............................................................................................................ 4 - 1

APlatform Controls

1-1 Controllers .................................................................................................... 4 - 2

APlatform Components

2-1 Platform Leveling Slave Cylinder .................................................................. 4 - 4

2-2 Platform Rotator ........................................................................................... 4 - 6

AJib Boom Components, Z-45/25J Models

3-1 Jib Boom ...................................................................................................... 4 - 7

3-2 Jib Boom Lift Cylinder .................................................................................. 4 - 8

APrimary Boom Components

4-1 Cable Track .................................................................................................. 4 - 9

4-2 Primary Boom ............................................................................................ 4 - 13

4-3 Primary Boom Lift Cylinder......................................................................... 4 - 16

4-4 Primary Boom Extension Cylinder .............................................................. 4 - 17

4-5 Platform Leveling Master Cylinder .............................................................. 4 - 18

ASecondary Boom Components

5-1 Secondary Boom ........................................................................................ 4 - 21

5-2 Secondary Boom Lift Cylinders .................................................................. 4 - 25

AKubota Z482-E Engine

6-1 Timing Adjustment ..................................................................................... 4 - 27

6-2 RPM Adjustment ........................................................................................ 4 - 27

6-3 Engine Drive Pulley .................................................................................... 4 - 27

Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy

August 2004

TABLE OF CONTENTS

Section 4 Rev Repair Procedures, continued

AGenerator

7-1 Generator Pulley ........................................................................................ 4 - 29

7-2 Generator Belts .......................................................................................... 4 - 30

7-3 Generator Voltage Regulator ...................................................................... 4 - 30

AHydraulic Pumps

8-1 Auxiliary Pump ........................................................................................... 4 - 33

8-2 Function Pump ........................................................................................... 4 - 33

BManifolds

9-1 Function Manifold Components (before serial number 17841) ..................... 4 - 34

9-2 Function Manifold Components (from serial number 17841 to 20379) ......... 4 - 38

9-3 Function Manifold Components (from serial number 20380 to 22565) ......... 4 - 40

9-4 Function Manifold Components (after serial number 22565)........................ 4 - 42

9-5 Valve Adjustments - Function Manifold ...................................................... 4 - 44

9-6 Jib Boom / Platform Rotate Manifold Components ..................................... 4 - 46

9-7 Turntable Rotation Manifold Components ................................................... 4 - 47

ATurntable Rotation Components

10-1 Rotation Hydraulic Motor (before serial number 18367) ............................... 4 - 48

10-2 Turntable Rotation Assembly (after serial number 18366) ........................... 4 - 50

AMotor Controller

11-1 Motor Controller .......................................................................................... 4 - 52

Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488

August 2004

TABLE OF CONTENTS

Section 5 Rev Fault Codes

Introduction ............................................................................................................ 5 - 1

A Fault Code Chart .................................................................................................... 5 - 3

Section 6 Rev Schematics

Introduction ............................................................................................................ 6 - 1

A Electrical Symbols Legend .................................................................................... 6 - 2

A Hydraulic Symbols Legend .................................................................................... 6 - 3

Power Cable Diagrams

A Power Cable Diagram (before serial number 16839) ............................................... 6 - 5

A Power Cable Diagram (from serial number 16840 to 21179) ................................... 6 - 6

A Power Cable Diagram (from serial number 21180 to 22050) ................................... 6 - 7

A Power Cable Diagram (after serial number 22050) .................................................. 6 - 8

Engine Panel Diagrams

A Engine Panel Diagram (before serial number 13361) .............................................. 6 - 9

A Engine Panel Diagram (from serial number 13361 to 14078) ................................ 6 - 10

A Engine Panel Diagram (from serial number 14079 to 14650) ................................ 6 - 11

A Engine Panel Diagram (from serial number 14651 to 16839) ................................ 6 - 12

A Engine Panel Diagram (from serial number 16840 to 17974) ................................ 6 - 13

A Engine Panel Diagram (from serial number 17975 to 21180) ................................ 6 - 14

A Engine Panel Diagram (from serial number 21181 to 22050) ................................ 6 - 15

A Engine Panel Diagram (after serial number 22050) ............................................... 6 - 16

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