Genie Z-25/8 Bedienungsanleitung

Service

Manual

Technical

Publications

First Edition Third Printing

Part No. 41314

•

Z-20 8

Z-25 8

Genie Z-20/8N & Genie Z-20/8 & Genie Z-25/8 Part No. 41314

First Editon • Third Printing

Introduction

Important

Read, understand and obey the safety rules and

operating instructions in the Genie Z-25/8 & Genie

Z-20/8 & Genie Z-20/8N 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 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.

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 other manuals. Please

write to the technical publications team in care of

Genie Industries, PO Box 97030, Redmond WA

98073-9730 USA.

If you have any questions, please call Genie

Industries.

FirstEdition: FirstPrinting,September1997

SecondPrinting,February1998

ThirdPrinting,April2000

Genie and "Z" are registered trademarks of

Genie Industries in the USA and many other

countries.

Printedonrecycledpaper

PrintedinU.S.A.

Contactus:

http://www.genielift.com

e-mail: [email protected]

Part No. 41314 Genie Z-20/8N & Genie Z-20/8 & Genie Z-25/8

First Edition • Third Printing

iii

Danger

Failure to obey the instructions and safety rules

in this manual and the Genie Z-20/8N &

Genie Z-20/8 & Genie Z-25/8 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-20/8N & Genie Z-20/8 & Genie Z-25/8 Part No. 41314

First Editon • Third Printing

SAFETY RULES

PersonalSafety

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.

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 sitiuation 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 special 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.

WorkplaceSafety

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 re-used. 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. 41314 Genie Z-20/8N & Genie Z-20/8 & Genie Z-25/8

First Edition • Third Printing

Theory of Operation

PowerSource

The Genie Z-20/8N & Genie Z-20/8 &

Genie Z-25/8 machines are powered by eight six-

volt (255 AH) batteries. Each 4-battery pack, is

wired in series/parallel to produce 24V DC. The

two battery packs are then wired in series to

produce 48V DC. The drive system uses 48V DC

and the control system uses 24V DC.

Hydraulic System

All machine functions are performed by the

hydraulic system. The hydraulic system is

pump. The lift and steer functions use pump #2.

The drive function utilizes pump #1 combined with

pump #2 for a total of 12 cc's displacement per

revolution. To protect from over-pressurization of

the hydraulic system, the pumps are provided with

a pressure relief valve set at 3500 psi (241 bar).

Activating a machine function is accomplished by

actuating or moving a toggle switch and/or control

handle, which sends voltage to the appropriate

directional control valve. The directional control

valve determines which direction the hydraulic fluid

will travel. The amount of hydraulic fluid volume is

determined by the proportional valve input voltage

from the boom function speed controller at the

platform controls. The boom lift cylinder and the jib

boom lift cylinder incorporate counterbalance

valves to prevent movement in the event of a

hydraulic line failure.

Electrical System

Drive speed limit switch

The drive speed limit switch, located in the boom

storage area, is used to restrict drive speed when

the boom is raised. An improperly functioning drive

speed limit switch will allow the boom to raise

and/or drive into an unsafe position.

MachineControls

The Genie Z-20/8N & Genie Z-20/8 &

Genie Z-25/8 machines are equipped with

operational controls which are found in two

locations: the ground controls, and platform

controls. All lift and drive functions are available at

the platform controls. Only boom functions are

available at the ground controls. Moving a boom

toggle switch in the direction indicated on the

control panel decal will indicate which boom

function will operate and its direction of travel.

The platform controls incorporates a boom

function speed controller which, by varying the

position of the controller, controls the amount of

voltage sent to the proportional valve. This

determines the speed at which the function will

operate.

The drive controller (joystick) is fitted with a

potentiometer that communicates the joystick

position with the motor controller. A thumb rocker

switch on the top of the joystick is used for

steering.

Washing electronic components is not suggested.

Instead, use compressed air to remove debris

from these components.

Genie Z-20/8N & Genie Z-20/8 & Genie Z-25/8 Part No. 41314

First Editon • Third Printing

Thispageintentionallyleftblank.

Part No. 41314 Genie Z-20/8N & Genie Z-20/8 & Genie Z-25/8

First Edition • Third Printing

Table of Contents

vii

Introduction

Important Information .....................................................................................................ii

Section One Safety Rules

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

Theory Of Operation...................................................................................................... v

Section Two Specifications

Machine and Performance Specifications, Z-25/8 Models ....................................... 2 - 1

Machine and Performance Specifications, Z-20/8 Models ....................................... 2 - 2

Machine and Performance Specifications, Z-20/8N Models..................................... 2 - 3

Hydraulic Specifications - All Models........................................................................ 2 - 4

Hydraulic Hose and Fitting Torque Specifications .................................................... 2 - 5

Section Three Scheduled Maintenance Inspections

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

Table A ..................................................................................................................... 3 - 2

Table B ..................................................................................................................... 3 - 2

Table C..................................................................................................................... 3 - 3

Table D..................................................................................................................... 3 - 3

Maintenance Inspection Report................................................................................ 3 - 4

Section Four Scheduled Maintenance Procedures

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

A-1 Inspect the Operator’s and Safety Manuals.................................................... 4 - 2

A-2 Inspect the Decals and Placards .................................................................... 4 - 2

A-3 Inspect for Damage and Loose or Missing Parts ............................................ 4 - 3

A-4 Check the Hydraulic Oil Level......................................................................... 4 - 3

Genie Z-20/8N & Genie Z-20/8 & Genie Z-25/8 Part No. 41314

First Editon • Third Printing

TABLE OF CONTENTS

viii

Section Four Scheduled Maintenance Procedures, continued

A-5 Check for Hydraulic Leaks.............................................................................. 4 - 4

A-6 Test the Platform and Ground Controls .......................................................... 4 - 5

A-7 Test the Auxiliary Power Operation ................................................................ 4 - 6

A-8 Test the Tilt Sensor ........................................................................................ 4 - 6

A-9 Test the Drive Speed Limit Switch.................................................................. 4 - 7

A-10 Perform 30 Day Service.................................................................................. 4 - 9

B-1 Check the Batteries ...................................................................................... 4 - 10

B-2 Inspect the Electrical Wiring ......................................................................... 4 - 11

B-3 Inspect the Tires and Wheels (including castle nut torque) .......................... 4 - 12

B-4 Test the Key Switch...................................................................................... 4 - 12

B-5 Test the Emergency Stop Buttons................................................................ 4 - 13

B-6 Test the Ground Control Override ................................................................ 4 - 13

B-7 Test the Horn................................................................................................ 4 - 14

B-8 Test the Foot Switch..................................................................................... 4 - 14

B-9 Test the Drive Brakes ................................................................................... 4 - 15

B-10 Test the Drive Speed - Stowed Position ....................................................... 4 - 16

B-11 Test the Drive Speed - Raised Position ........................................................ 4 - 17

B-12 Test the Alarm Package (if equipped) .......................................................... 4 - 18

B-13 Perform Hydraulic Oil Analysis ..................................................................... 4 - 19

B-14 Check the Electrical Contactors.................................................................... 4 - 19

B-15 Replace the Hydraulic Tank Return Filter ..................................................... 4 - 19

C-1 Bleed the Jib Boom Rotator.......................................................................... 4 - 21

D-1 Test or Replace the Hydraulic Oil ................................................................. 4 - 22

Part No. 41314 Genie Z-20/8N & Genie Z-20/8 & Genie Z-25/8

First Edition • Third Printing

TABLE OF CONTENTS

Section Five Troubleshooting Flow Charts

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

1 All Functions Will Not Operate........................................................................ 5 - 3

2 Pump Motor Will Not Operate......................................................................... 5 - 6

3 Auxiliary Functions Inoperative ....................................................................... 5 - 8

4 All Functions Inoperative, Power Unit Starts and Runs ................................ 5 - 10

5 Ground Controls Inoperative, Platform Controls Operate Normally .............. 5 - 11

6 Platform Controls Inoperative, Ground Controls Operate Normally .............. 5 - 12

7 Boom Up Function Inoperative ..................................................................... 5 - 15

8 Boom Down Function Inoperative................................................................. 5 - 17

9 Jib Boom Up Function Inoperative................................................................ 5 - 19

10 Jib Boom Down Function Inoperative ........................................................... 5 - 22

11 Jib Boom Rotate Left Function Inoperative................................................... 5 - 25

12 Jib Boom Rotate Right Function Inoperative ................................................ 5 - 28

13 Steer Left Function Inoperative..................................................................... 5 - 31

14 Steer Right Function Inoperative .................................................................. 5 - 32

15 All Drive Functions Inoperative, All Other Functions Operate Normally........ 5 - 33

16 Drive Forward Function Inoperative.............................................................. 5 - 36

17 Drive Reverse Function Inoperative.............................................................. 5 - 37

18 Machine Will Not Drive At Full Speed ........................................................... 5 - 38

19 Machine Drives At Full Speed With Platform Raised.................................... 5 - 41

20 Brake Release Function Inoperative............................................................. 5 - 42

Genie Z-20/8N & Genie Z-20/8 & Genie Z-25/8 Part No. 41314

First Editon • Third Printing

TABLE OF CONTENTS

Section Six Schematics

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

Electrical Components.............................................................................................. 6 - 2

Electrical Symbols Legend ....................................................................................... 6 - 4

Abbreviation Legend................................................................................................. 6 - 5

Electrical Schematic,

Z-25/8 (before serial number 229)

Z-20/8 (before serial number 125)

Z-20/8N (before serial number 968)................................................................ 6 - 7

Electrical Schematic,

Z-25/8 (after serial number 228)

Z-20/8 (after serial number 124)

Z-20/8N (after serial number 967) .................................................................. 6 - 8

Ground Control Panel Wiring Diagram ..................................................................... 6 - 9

Platform Control Box Wiring Diagram,

Z-25/8 (before serial number 229)

Z-20/8 (before serial number 125)

Z-20/8N (before serial number 968).............................................................. 6 - 10

Platform Control Box Wiring Diagram,

Z-25/8 (after serial number 228)

Z-20/8 (after serial number 124)

Z-20/8N (after serial number 967) ................................................................ 6 - 11

Power Cable Diagram ............................................................................................ 6 - 12

Hydraulic Symbols Legend..................................................................................... 6 - 14

Hydraulic Schematic,

Z-25/8 (before serial number 229)

Z-20/8 (before serial number 125)

Z-20/8N (before serial number 968).............................................................. 6 - 15

Hydraulic Schematic,

Z-25/8 (after serial number 228)

Z-20/8 (after serial number 124)

Z-20/8N (after serial number 967) ................................................................ 6 - 16

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