Preventive Maintenance Manual

Genie Z-34/22N

Preventive Maintenance Manual

April 2016

Table of Contents

Safety Rules

Personal Safety

Workplace Safety

Introduction

Preventive Maintenance

Unit & Surrounding Area

Pre-Operation Inspection

Platform & Ground Controls

Auxiliary Power Operation

Tilt Sensor

Limit Switches

Batteries

Electrical Wiring

Tires & Wheels

Brake Configuration

Drive Hub Oil

Key Switch

Ground Control Override

Platform Self-Leveling

Horn, Foot Switch & Drive Enable System

Drive Brakes

Drive Speed

Alarm Package (if equipped)

Turntable Rotation Stop

Turntable bearing bolts

Turntable Rotation Bearing & Worm Drive Gear

Electrical Contactors

Boom Wear Pads

Free Wheel Configuration

Hydraulic Return Filter

Hydraulic Oil

Wheel Bearings

Troubleshoot

Problem #1

Problem #2

Problem #3

Problem #4

Problem #5

Problem #6

Citation

Safety Rules

Personal Safety

Personal and safely operation of the machine should be top priority. Anyone working on or around the machine must aware of all the safety hazards.

Workplace Safety

Be sure to wear protective gears such as goggles and other protective clothing. Be aware of potential crushing hazards such as moving parts and free swinging components

Introduction

In mostconstruction work environments, major assets such as electrical wiring, water pipe systems or HVAC units are located in high or hard to reach places. During preventive maintenance, a mobile mechanical lift is required to proceed. These mobile lifts pose many dangerous hazards and require their own preventive maintenance procedure and schedule. While operating these lifts, human lives are put in danger and threaten by the following hazards: electrocution hazards, tip-over hazards, fall hazards, collision hazards, explosion hazard, and burn hazards. Given this long list of hazards, scheduled maintenance must be performed on these mobile boom lifts in order to greatly minimize the chance for these hazards from occurring.

Preventive Maintenance

Unit & Surrounding Area

Clean and remove accumulations of dirt and debris from unit casing and unit area. Remove all obstructions. Ensure all safety and instructions signage are in place and legible.

Pre-Operation Inspection

Check entire machine for damages and cracks in welds or structural components.
Check the hydraulic power unit oil level. Ensure there are no leaks.

Platform & Ground Controls

As a safety feature, selecting and operating ground controls will override the platform controls, including the Emergency Stop button.
Test to ensure the emergency stop button stops all the machine functions. Check that each function operates smoothly and be free of hesitation, jerking and unusual noise.

Auxiliary Power Operation

Test to ensure the auxiliary power system operates in the event of a main power loss

Tilt Sensor

The alarm should be heard at the ground control. If the alarm is not heard, replace the alarm in the platform Ensure the tilt sensor alarm sound in the platform when the incline of the machine exceeds the rating on the serial plate. If the alarm is not heard at the ground control, replace the alarm in the platform.

Limit Switches

Test the drive speed limit switch for proper operation.

Batteries

Disconnect each battery pack from the machine and avoid contact with battery acid. Neutralize battery acid spills with baking soda and water.
Ensure the battery cable connections are free from corrosion. Check the battery acid level. If needed, replenish with distilled water to 1/8 inch below the bottom of the battery fill tube. Do not overfill.

Electrical Wiring

Contact with hot or live circuits could result in death or serious injury. Remove all rings, watches and other jewelry.
Inspect the electrical power and relay panel, ground control panel and turntable manifold wiring for burnt, chafed, corroded and loose wires. Repair/replace if necessary.

Tires & Wheels

Check the tire surface and sidewalls for cuts, cracks and unusual wear. Check each wheel for damage, bends and cracks. Check lug nuts for tightness (125ft-lbs).

Brake Configuration

Check each drive hub disconnect cap to be sre it is in the engaged position.

Drive Hub Oil

Replace each drive hub’s oil and ensure the oil level is even with the bottom of the side hole.

Key Switch

Pull out the Emergency Stop button to the on position at both the ground and platform controls. Check that the key switch dictates which part of the machine is operable.

Ground Control Override

Pull out the Emergency Stop button at the ground controls. Check that all boom functions remain operational.

Platform Self-Leveling

Turn the key switch to ground controls and pull out the red Emergency Stop button to the on position at both the ground and platform controls.
Raise and lower the primary boom through a full cycle. Check that the platform remains level at all times.

Horn, Foot Switch & Drive Enable System

Ensure the horn, foot switch and drive enable system is operational.

Drive Brakes

Collision hazard. Be sure that the machine is not in free-wheel or partial free-wheel configuration.
With the boom in the stowed position, test the brakes for proper operation. The drive brake function should operate smoothly, free of hesitation, jerking and unusual noise.

Drive Speed

Check that the drive function respond quickly and smoothly to operator control under both the stowed and raised position.

Alarm Package(if equipped)

Turn the key switch to ground controls and pull out the red Emergency Stop buttons to the on position at both ground and platform controls. Check that the beacon is on and flashing.
Move each toggle switch to the down position, hold for a moment then release it. Check that the descent alarm sounds.
Move the drive joystick off center in either direction, hold for a moment then release it. Check that the travel alarm sounds.

Turntable Rotation Stop

Turn the key switch to platform controls and pull out the red Emergency Stop buttons to the on position at both ground and platform controls.
Check the rotation limits of the turntable, movementshould stop when the primary boom reaches midpoint between the steer tires.

Turntable bearing bolts

Keep hands away from the cylinder and all moving parts when lowering the secondary boom. Raise the secondary boom and place a safety chock on the secondary boom lift cylinder. Carefully lower the secondary boom onto the lift cylinder safety chock. Confirm that each turntable mounting bolt is torqued in sequence to the specification torque of 180ft-lbs.
Raise the secondary boom and remove the safety chock. Lower the secondary boom to the stowed position. Open the latch on the battery packs and swing them out to expose the turntable bearing bolt access hole. Confirm that each turntable mounting bolt is torqued in sequence to specification torque of 180ft-lbs.

Turntable Rotation Bearing & Worm Drive Gear

Use Multipurpose Grease
Grease the fittings located on the bulkhead next to the hydraulic power unit. Pump grease into bearings by rotate turntable 4-5 inches at a time and repeat until entire turntable is greased.
Grease (3) fittings on the worm drive housing.

Electrical Contactors

Contact with hot or live circuits could result in death or serious injury. Remove all rings, watches and other jewelry.
Remove the drive chassis cover from the non-steer end of the machine and check the contacts for excessive burns or pitting. Replace the contactors if any damage is found.

Boom Wear Pads

Measure each wear pad. Replace the wear pad once it reaches the minimum allowable thickness of 3/8".
Extend and retract the primary boom through the entire range of motion to check for tight spots that could cause binding or scraping.

Free Wheel Configuration

Collision Hazard. Select a work site that is firm and level. Failure to engage the drive hubs could cause serious injury and property damage.
Lift wheels off the ground and plce jack stand under drive chassis for support. Disengage drive hubs and manually rotate each non-steering wheel. Ensure each wheel rotates with minimum effort. Engage drive hubs and remove stand after testing.

Hydraulic Return Filter

Bodily injury hazard. Beware of hot oil. Contact with hot oil may cause severe burns.
Remove and replace the filter element from the filter housing on top of the hydraulic tank. Clean the area around the filter when finished.

Hydraulic Oil

Use Chevron Rykon MV or eqivalent hydraulic oil.
First close the hydraulic shutoff valve located and the hydraulic tank, then Drain and replace the hydraulic oil.

Wheel Bearings

Use Chevron Ultra-duty grease, EP NLGI 2 (lithium based) or equivalent
Grease the steer axle wheel bearings.

Troubleshoot

Problem #1

Condition: Machine will not drive. Controller fault indicator light may or may not be on at the platform controls.“COMMUNICATION ERROR”

Possible Causes: The key switch or Emergency Stop button(s) was cycled on and off faster than 5 seconds OR controller sensed an internal error during start up.

Solution: Push in the ground control Emergency Stop button to the OFF position and wait for 5 seconds. Pull out the ground control Emergency Stop button to the ON position. If problem persists, replace the motor controller.

Problem #2

Condition: Machine will not drive. Controller fault indicator light on at the platform controls. “HW FAILSAFE 1-2-3”

Possible Causes: The motor controller failed self-test.

Solution: Replace the motor controller.

Problem #3

Condition: Machine will not drive. Controller fault indicator light on at the platform controls. “M- SHORTED”

Possible Causes: The motor controller has an internal short between M- and Bterminals.

Solution: Test the motor controller.

Problem #4

Condition: Machine will not drive. Controller fault indicator light on at the platform controls. “FIELD OPEN”

Possible Causes: Motor wiring is loose OR motor is defective OR motor controller has an internal short.

Solution: Check for loose or open connections at the drive motors and motor controller OR replace the defective drive motor OR test the motor controller. See Repair Section.

Problem #5

Condition: Machine will not drive. Controller fault indicator light on at the platform controls. “ARM SENSOR”

Possible Causes: Defective motor controller.

Solution: Replace the motor controller.

Problem #6

Condition: Machine will not drive. Controller fault indicator light on at the platform controls. “FLD SENSOR”

Possible Causes: Defective motor controller.

Solution:Replace the motor controller.

Citation

Genie Service Manual. (2008, February). Retrieved April 2, 2016, from And Service Manuals/data/Service/Z Booms/36540.pdf

Genie Industries

First Edition: First Printing June, 1996

Second Printing February, 2000

First Edition: Third Printing August, 2008

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