Par ts Manual Z-45/25 TM Z-45/25J. Par ts and Service Supplement. Positive Air Shutdown Valve. Serial Number Range

Transcription

1 Par ts Manual Par ts and Service Supplement Positive Air Shutdown Valve Serial Number Range TM Z-45/25 TM Z-45/25J Serial Number Range from Z452513A Part No Rev B1 January 2016

2 Introduction Important Read, understand and obey the safety rules and operating instructions in the Genie Z-45/25 and Genie Z-45/25J Operator's Manual before attempting any maintenance or repair procedure. This manual provides detailed parts and service information 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. This Parts and Service Manual Supplement provides service parts information and electrical schematics for the recently released Positive Air Shutdown System, which are not included in your parts or service manuals. Please add this parts information and electrical schematics to the parts and service manuals for your machine. Technical Publications Genie 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. Contact Us: awp.techpub@terex.com Copyright 2011 Terex Corporation Rev B May 2013 First Edition, Second Printing "Genie" and "Z" are registered trademarks of Terex South Dakota, Inc. in the USA and many other countries. Printed on recycled paper Printed in U.S.A. 2 Z-45/25 Z-45/25J Part No

3 Revision History Revision Date Section Procedure / Schematic Page / Description A 1/2013 New release B 5/2013 Engine Pg. 6, Pg. 7 Chassis Pg. 8, Pg. 9 B1 1/2016 Engine Pg. 7 REFERENCE EXAMPLES: Kubota Engine_Section 2_Specifications. A-6,B-3,C-7_Section 3_Maintenance Procedure. 3-2, 6-4, 9-1_Section 4_Repair Procedure. Fault Codes_Section , 6-56, 6-104_Section 6_Schematic Page #. Electronic Version Click on any procedure or page number highlighted in blue to view the update. Part No Z-45/25 Z-45/25J 3

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5 Introduction Table of Contents Introduction Important Information... 2 Section 1 Service Parts Engine Components... 4 Chassis Components... 6 Section 2 Maintenance Procedures Maintenance Inspection Report...10 A-3.1 Test the Automatic Engine Overspeed Control System...11 A-9.1 Lubricate the Lever Shaft...12 Section 3 Schematics Introduction...13 System Wiring Diagram...14 Ground Control Box Wiring Diagram...15 Part No Z-45/25 Z-45/25J 5

6 Section 1 Parts Information January 2016 Engine Components Z-45/25 Z-45/25J Part No

7 Section 1 Parts Information ENGINE COMPONENTS Item Part No. Description Qty Solenoid, 12V DC Hex Nut, 1 /4-20, GR Flat Washer, 1 /4 inch Screw - HHC, 1 /4-20 x 0.75 inch, GR Clevis Yoke, 1 / Nut, 1 /4-28, GR Screw - HHC, 1 /4-20 x 1 inch, GR Nylock Nut, 1 / Circuit breaker, 15 Amp Screw, Phillips, x flat Washer, # Nylock nut, Screw, Phillips, x Relay, 12 VDC, 70 Amp Gasket - Deutz Adapter Nut, Nylock, M8 x Washer, Flat, M Screw, SHC, M x 35, 12.9, Zag Valve - Positive Air Shutdown with Deutz Adapter... 1 Part No Z-45/25 Z-45/25J 7

8 Section 1 Parts Information January 2016 Chassis Components 1 2 Ground Control Box Z-45/25 Z-45/25J Part No

9 Section 1 Parts Information CHASSIS COMPONENTS Item Part No. Description Qty Wire Harness - Positive Air Shutdown Decal - Test Toggle Switch, SPDT 3 position, momentary (Test) (includes mounting fasteners) Toggle Switch Boot Screw - PHPH, 6-32 X Nylock Nut, 1 / Flat Washer, 1 /4 inch Screw - HHC, 1 /4-20 x 2.5 inches, GR Positive Air Shutdown Controller Positive Air Shutdown System Software Control Module Control Module Label Part No Z-45/25 Z-45/25J 9

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11 Section 2 Maintenance Procedures Scheduled Maintenance Procedures About This Section This section contains detailed procedures for each scheduled maintenance inspection. Observe and Obey: Maintenance inspections shall be completed by a person trained and qualified on the maintenance of this machine. Scheduled maintenance inspections shall be completed daily, quarterly, annually and every 2 years as specified on the Maintenance Inspection Report. Failure to properly complete each inspection when required may cause death, serious injury or substantial machine damage. Immediately tag and remove from service a damaged or malfunctioning machine. Repair any machine damage or malfunction before operating machine. Keep records on all inspections for three years. Unless otherwise specified, perform each procedure with the machine in the following configuration: Machine parked on a firm, level surface Boom in the stowed position Turntable rotated with the boom between the non-steering wheels Turntable secured with the turntable rotation lock Key switch in the off position with the key removed Wheels chocked All external AC power disconnected from the machine Each procedure includes a description, safety warnings and step-by-step instructions. Symbols Legend 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. Red used to indicate the presence of an imminently hazardous situation which, if not avoided, will result in death or serious injury. Orange used to indicate the presence of a potentially hazardous situation which, if not avoided, could result in death or serious injury. Yellow with safety alert symbol used to indicate the presence of a potentially hazardous situation which, if not avoided, may cause minor or moderate injury. Yellow without safety alert symbol used to indicate the presence of a potentially hazardous situation which, if not avoided, may result in property damage. Indicates that a specific result is expected after performing a series of steps. Indicates that an incorrect result has occurred after performing a series of steps. Part No Z-45/25 Z-45/25J 11

12 Section 2 Maintenance Procedures January 2016 Maintenance Inspection Report Model Serial number Date Hour meter Machine owner Inspected by (print) Inspector signature Refer to the Genie Z-45/25 and Z-45/25J Service Manual for scheduled machine maintenance procedures. The following scheduled maintenance procedures will need to be performed in addition to regularly scheduled machine maintenance inspections as outlined in the Service Manual. Checklist A - Rev A Y N R A-3.1 Lubricate lever shaft Perform every 100 hours: A-9.1 Lubricate lever shaft Inspector title Inspector company Instructions Make copies of this report to use for each inspection. Store completed forms for three years. If any inspection receives an N, tag and remove the machine from service, repair and re-inspect it. After repair, place a check in the R box. Legend Y = yes, acceptable N = no, remove from service R = repaired Comments 12 Z-45/25 Z-45/25J Part No

13 Section 2 Maintenance Procedures Maintenance Procedures A-3.1 Test the Automatic Engine Overspeed Control System Genie specifications requires that this procedure be performed daily or every 8 hours, whichever comes first. Regular testing the automatic engine overspeed control system is essential to safe machine operation. Continued use of an improperly lubricated lever shaft could result in a positive air shutdown control system malfunction during an engine overspeed condition. Component damage may result. 5 Wait approximately 5 to 10 seconds for the solenoid valve to reset. 6 Start the engine from the ground controls. Result: The engine should start and operate normally. Result: The engine does not start. Consult the Genie Service Department. Note: Perform this procedure with the machine on a firm, level surface. 1 Pull out the red Emergency Stop Button to the on position at both the ground and platform controls. 2 Turn the key switch to ground control. Start the engine from the ground controls and allow it to idle. 3 Locate the test toggle switch on the side of the ground control box. Move and hold the toggle switch to the TEST position. 4 Activate high idle (rabbit symbol). Result: The engine should shut off. Result: The engine does not shut off. Consult the Genie Service Department. Part No Z-45/25 Z-45/25J 13

14 Section 2 Maintenance Procedures January 2016 MAINTENANCE PROCEDURES A-9.1 Lubricate the Lever Shaft a Genie specifications require that this procedure be performed every 100 hours or monthly, whichever comes first. Perform this procedure more often if dusty conditions exist. Lubrication to the lever shaft is essential to safe machine operation. Continued use of an improperly lubricated lever shaft could result in a positive air shutdown control system malfunction during an engine overspeed condition. Component damage may result. 1 Locate the lever shaft on the shutdown valve assembly. 2 Apply a liberal coating of grease to the shaft end surfaces on both sides of the valve. Refer to Illustrations 1 and 2. d c b Illustration 1 a solenoid b shutdown valve assembly c lever shaft d air intake tube Grease Specification Chevron Ultra-duty grease, EP NLGI 2 (lithium based) or equivalent c b a Illustration 2 14 Z-45/25 Z-45/25J Part No

15 Section 3 Schematics Schematics About This Section Electrical Schematics Observe and Obey: Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine. Immediately tag and remove from service a damaged or malfunctioning machine. Repair any machine damage or malfunction before operating the machine. Before Troubleshooting: Read, understand and obey the safety rules and operating instructions in the appropriate operator's manual on your machine. Be sure that all necessary tools and test equipment are available and ready for use. General Repair Process Malfunction discovered Return to service problem solved Identify symptoms problem still exists Inspect and test Troubleshoot Perform repair Part No Z-45/25 Z-45/25J 15

16 Section 3 Schematics January 2016 System Wiring Diagram P20BAT RD/12 CB8 15A F11 70A V DC CR C1B-X BR C1B-S RD C1B-A RD HOLD R20BAT RD/12 CR6 #87 J196-7 WH J57-B J BK CR6 #85 J WH CR6 #86 J196-1 BR GND J196-2 RD P134BAT TS74-2 J OR/BK C41RPM TB41 J196-9 GR TS74-1 B A C J57 TROMBETTA PULL COIL HOLD COIL GROUND U18 CONTROL MODULE PULL COIL PULL RELAY (GND) HOLD COIL RELAY -12V +12V RPM SIGNAL TEST SWITCH GROUND TB134B TB41B C1B-Q C1B-V OR/BK C1B-W RD TS74 TEST SWITCH 16 Z-45/25 Z-45/25J Part No

17 1 January 2016 Section 3 Schematics Ground Control Box Wiring Diagram Genie Industries TROMBETTA 1 TO REMOVE: 1 START RELAY 2 Push gently 2 TACHOMETER 3 and lift 3 START INPUT 4 4 AUX PWR UNIT 5 5 GROUND U1 (ISM) 6 6 BATTERY 7 7 TO KEY SW (DIESEL ONLY) 8 8 JUMP TO 7 (GAS ONLY) IGN OR FUEL ON TEMP OR PRESS FAULT 12/24 Volt IGNITON/START MODULE P/N C6 PIN FUNCTIONS D C TERMINAL BASE (TB) B A 1 PRIMARY BOOM UP 1 WH/12 RD/12 BK/ PRIMARY BOOM DOWN TURNTABLE ROTATE LEFT 2 4 B J57 A C 5 TURNTABLE ROTATE RIGHT 5 INSTALL ON ENGINE SIDE F11 70A PULL RLY BK J P20BAT RD/ CR6 R20BAT RD/12 HOLD BATTERY P20BAT RD/12 HOLD COIL WH J CB8 15A CONTROL MODULE U18 P20BAT RD/12 BATERY(+) PULL IN WH J196-7 J196-1 GND BR HOLD R20BAT RD/12 CR6#87 GND BK GND BR J196-9 J J196-2 J196-1 J J196-7 J TEST GR TS74-1 C41RPM OR/BK TB41 P134BAT RD TS74-2 GND BR PULL RLY BK CR6#85 PULL IN WH HOLD COIL WH CR6# OIL PRESSURE G1 WATER TEMP G2 BATTERY INDICATOR G3 H6 RD CB3 RD CB2 WH CR17 WH CR17 WH FUSE WH CR2 BR C1B-X 7 PRIMARY BOOM EXTEND 7 8 PRIMARY BOOM RETRACT 8 10 SECONDARY BOOM UP SECONDARY BOOM DOWN PLATFORM LEVEL UP PLATFORM LEVEL DOWN PLAT ROTATE LEFT/JIB UP PLAT ROTATE RIGHT/JIB DOWN VOLT BATTERY POWER VOLT IGN. POWER VOLT IGN. POWER VOLT IGN. POWER VOLT TO PLATFORM VOLT TO PLATFORM KEYSWITCH POWER CB1 POWER OIL PRESSURE ANDTEMP SW AUXILIARY PUMP MOTOR STROKE DRIVE FORWARD DRIVE REVERSE BRAKE START ENGINE GLOW PLUG OR LP HIGH RPM ALTERNATOR PULSE PICKUP GENERATOR OPT ALARMS OPT KS POWER A KS POWER 134A GND MAIN GROUND GND GND MAIN GROUND GND GND MAIN GROUND GND RD OR/BK C5 SOC CB7 10A C7B BAT AUX C3B PIN ENGINE 12V DC TO PLAT 19/18 CABLES WH ISM 9 (CE SEE U34) TB134 RD CR1 CR2 CR4 CR5 TS74 TEST SWITCH C1B-W GR TEST BAT AUX CB3 15A CB4 15A AUX BAT CR17 CR23 C1B-Q C1B-V C1B-N C1B-S C1B SOC C1B-W C1B-X 19/18 CABLES C1B-W TEST GR TS74-1 C1B-V C41RPM OR/BK TB41 C1B-A P134BAT RD TS74-2 C1B-X GND BR Part No Z-45/25 Z-45/25J 17