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Service Manual - Genie Industries

1. A B C D E F H K L M JIB BOOM 1 JIB ROTATE Z30NRJ PLATFORM ROTATE y je 0 fs COUNTERBALANCE VALVES LI HT Joke T Ue SCHEMATIC ITEM RATIO PRESSURE ROTATE MANIFOLD i lt Q d w O rw lE ROTATE MANIFOLD JIB BOOM lt iy PLATFORM 2 BF BH 31 2500 PSI EI Lodo wol 1 Bo BK BL 154 8000 PSI Bl 8300 psi BL BM BN B 3000 PSI _ pons L ze bat m REA UN 524 Lem BA BB 4 51 3000 PSI ART JR2 J1 J2 PRI PR2 BD BE 3 1 3200 BJ BM BN 81 8800 PSI Cy O EE 3 9 025 Inch CHECK VALVES p _06 AD 0 3 SCHEMATIC ITEM DESCRIPTION 1 14 L min CA PILOT VALVE D NE PLATFORM LEVELING 0 0 TT TT TMRRAOOMMANEQIn OS SLAVE CYLINDER JIB BOOM MANIFOLD 4 S a q EXTENSION CYLINDER EXTENSION CYLINDER Z30N Z34N 73400 Z30NRJ SECONDARY AM CYLINDER STEER t3 ri 0 032 inch CYLINDER Pod 081 P TURNTABLE gt
2. Genie A TEREX BRAND Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N Part No 139378 INHOA V 1d NOTES 4 TURNTABLE TILT ALARM LED OPTION 7 ON 2 34 22 MODELS THIS LOCATION IS USED FOR 1549 WORK LIGHT OPTION 1 15 rs 9 bo 077 Hi 05 7512 7 2 OOO H TS7 RO Dsow Q RSS esp pers JB LE TS11 5 OMO OD E QO 2 D D u gt tO NC NCQ TS13 TS10 5 2 2m 2 boo gt lt i 818 H ago 7910 e 158 gt 071 E Lo 9 53 5 8 mi 073 er 3 or 3 s 8 1 8 5 ES 5 5 48 RD BK z zo Imo 2 TS49 5 d 5 8 I ST 8 5 al 2 3 o WH RD
3. Am i a H 1 NOTES peu du x MM ul 1 gt gt TURNTABLE ALARM LED OPTION ON 2 34 22 MODELS THIS LOCATION IS USED FOR TS49 WORK LIGHT OPTION lox M E OJ 035 2 Y T515 5 5 er N97 51 Li 090 nr 4 077 EDS ps0 P3 8 n RO 040 D Y 028 7O NO O 9095 a ee gt g L LO C47 3 _ JIB ERR DAU Dau UT 2
4. 78 7 1 Function Manifold Components 78 7 2 Valve Adjustments Function 82 7 3 Jib Boom and Platform Jib Boom Rotate Manifold Components 85 TA Valve danti ite Utd e ami i Ga ao 87 Turntable Rotation Components 90 8 1 Turntable Rotation Hydraulic Motor sse 90 Steer Axle 4 444 4 0 10 91 9 1 Hub and 91 Non steer Axle Components 93 10 1 Motor Controller nre 93 Genie BRAND Part No 139378 Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N xi September 2015 __ S T Table of Contents Section 5 Section 6 xii gi 94 94 AA 99 99 Electrical Symbol Legend 100 Hydraulic Symbols 101 Limit Switch Location Legend anina ANENA 102 Electr
5. 0 464 2 TB15 814 B Q g Fi 8 3 8 T C40LS OR C52 2 WH iz cma _ 4 z CRIBA 4 re 9 9 Eu r gt pt 2 D C21 1 C20 1 A A 4 4 C21 2 C20 2 e e e GROUND BR mu 55 ra EET 3 SCHEMATIC PLATFORM LEVEL CUTOUT ES0276N September 2015 Service Manual CTE Option CE Models L G H J K M BR 1 CR18A CRI8B PLATFORM LEVEL UP PLATFORM LEVEL DOWN 2 C15PLD OR BK C21 1 CI4PLU OR C20 1 3 C40LS1 OR CR18A 30 Ve 4 C14PLU OR C4B 2 OR TS59 C14PLU OR 18 86 14 PLATFORM LEVEL UP 18 PLATFORM LEVEL DOWN 15 CI8PLD ORIBK CR16B406 5 P22BAT BK 32 4 P22BAT BK KSI P22LS 10 1 E AN PLATFORM gt 2 GR4 30 6 e P134BAT RD LS17 38 1 5 S 184 LOAD WEIGHING SW 12 1 184 G _PIS4BAT BK LSS 7 3 lt WH FH 7 _____ 134 LOAD WEIGHING LIM SW 12 2 _ 184 O TIS r GROUND BOLT 8 E WIRING DIAGRAM x Genie Part No 139378 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N 113 September 2015 pam ui
6. K WIRES FROM CONNECTOR TO CONNECTOR DESCRIPTION CIRCUIT RD WH FLASH BEACON OPT 134 RD C32 1 KEYSWITCH POWER RD WH TILT WH C7B 2 134 RD KSI 4 KEYSWITCH POWER Pi84BAT BR CB2 BK FLASH BEACON 52 BR MH BR GR4 GROUND BATGND BR 8 2 BR 7 3 52 BR BR SP GROUND BATGND RD WH CRS 48 RD AWH MH RDAWH SP BRAKE RELEASE ORRD CRI 4 42 C49 10 OR RD L3 SWITCHED 48V 42 4 1 11 37 BL BK MH STEER RIGHT C378CW sci BLCiB 19 38 BL MH STEER LEFT 635566 RD CRS RD 27 RD SP AUXILIARY PUMP C27AUX 10 2 BK C23 4 22 BK SP BK CR4 424V TO PLATFORM 22 TB36 TB37 GR WH CR3 19 GRAWH MH LIFT PUMP C19LPE eese GAMH C4B 7 18 GRAWH SP LIFT PUMP ORRD C amp 1 OR RD C4B 4 16 OR RD CR5 DRIVE ENABLE CieDE 4 18 ORBK MH OR BK 8P PLATFORM LEVEL DOWN _ C15PLD OR C4B2 14 OR MH OR SP PLATFORM LEVEL UP C14PLU BK C83 BLAWH C3B 12 12 FOOTSWITCH Ci2FT amp BL BK 11 BLBKMH 5 SECONDARY ROOM DOWN 11580 BLC3B 10 10 BL MH BL SP SECONDARY BOOM UP C10SBU C3B 8 8 BKWH MH PRIMARY BOOM RETRACT C8
7. Fault Code Programmer Condition Possible Causes Solution Diagnostic Display Fault code LED COMMUNICATION Machine will not drive The key switch or Push in the ground is off oris on but ERROR Emergency Stop control red Emergency not blinking button s was cycled Stop button to the off on and off faster than position and wait for 5 seconds OR 5 seconds Pull out the controller sensed an ground control red internal error during Emergency Stop start up button to the on position If problem persists replace the motor controller 1 Normal operation 12 HW FAILSAFE 1 2 3 Machine will not drive The motor controller Replace the motor failed self test controller 13 M SHORTED Machine will not drive The motor controller Test the motor has a internal short controller See Repair between M and B Section terminals FIELD OPEN Machine will not drive Motor wiring is loose Check for loose or OR motor is defective open connections at OR motor controller the drive motors and has an internal short motor controller OR replace the defective drive motor OR test the motor controller See Repair Section ARM SENSOR Machine will not drive Defective motor Replace the motor controller controller FLD SENSOR Machine will not drive Defective motor Replace the motor controller controller Genie 96 Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N Part 139378 September 2015 Service Ma
8. mE PINK WIRES 6 17 E WH B 21 22 BK 8 E Bi 1 RD JIB CABLE 8 BLAIIB 2 WH SE usu gem sail on ro IC E WIRES GKT MAHT cL PINK WIRES CIRCUITE ALL LIMIT SWITCHES SHOWN WITH THE BOOM IN ORB E YLJIB SHE ORUS Exc WB 1 THE STOWED POSITION WHERE NOTED E UBDOWN 2 BL 8 5 1 IB DOWN PLAT L PLATFORM 2 BL C18PRR C 7 1 C43JU ROTATE LEFT BK cau 4 6440 4 WH C44JD 5 YL C46JRL Sam C47JRR FE BR JIB 7 NC BR JIB ESS4DCU GROUND GROUND 8 gt 8 BR GND 8 BR GND Genie A TEREX BRAND 108 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N Part No 139378 September 2015 Service Manual LVI BCI Option Wiring Diagram A B D E H K L M 1 Qu 2 C7B Ts9 1757 2 O 2 2 8 x MN o D
9. TERMINAL BASE TB DESCRIPTION CIRCUIT WIRES FROM CONNECTOR TO CONNECTOR RD WH FLASH BEACON OPT 134 RD C32 1 KEYSWITCH POWER 1 WIRES CIRCUITE FROM DESCRIPTION RDAWH TILT WH 2 134 RD KSl 4 KEYSWITCH POWER 1 WH LS1 LS2 JUNCTION BR CB2 BK FLASH BEACON 52 BR MH BR CR4 GROUND BATGND BK J2 cts 6524 182 184 JUNCTION 2 OTRA 52 BR SP GROUND BAT ND OR BK CA7JRR coms 66 P JIB ROTATE RIGHT Z30N RJ ONLY RID WH CRS 48 RDWH MH RDWH SP BRAKE RELEASE RASBRK GER 805 JE ROTATE LEFT OR RD OR1 028 4 42 OR RD 049 10 OP RD L3 SWITCHED 48V R42BAT Gane Bais Em Tessin TEDORA 16 sueco BL K C1B 11 37 BL BK NH STEER RIGHT ca7scw an nep Bm STEER LEFT Gaesco on 52 2 C48 0 CH OFF LIMIT SPEED RD CRS RD C1B 1 27 RD SP AUXILIARY PUMP C27AUX Wiro m Ge Gs cH IBYETICK E 10 1 BK C32 4 22 BK CR4 424V TO PLATFORM 22 m E BE 7 GRMH CRS 19 GR WH MH LIFT PUMP mm mm CBE JE GRAWH C4B 7 18 GR WH SP LIFT PUMP C1I9LPE m usc Swine Por 8 1 C4B 4 18 OR RD CR5 DRIVE ENABLE C16DE ADEK aiis nem ADEM On CAES 15 ORBICMH PLATFORM LEVEL DOWN C15PLD GREK 2496 TB 57 SP PLATFORM ROTATE RIGHT ORCAB2 14 oRMH ORSP PLATFO
10. C19LPE GR WH 7 073 C44JD GR BK 2 6 C2PBD RD BK 2 C1PBU RD C3P 1 C14PLU OR 2 OR BK C2P 3 LO OR C2P 2 C15PLD OR BK C4P 3 C8PBR BK WH C8P 8 BK C3P 7 Ci3DEL BL RD C4P 1 ORG RD BRN C378CW C1P 11 BL 10 RD 525 066 LO NOO O O4 P3 P2 BCI P24BAT WH C9P 2 DP1 WH 4 WH BK 1 5 Ca2JSL WH RD C1P 6 1123456789110 C29J8H RDWH C1P 3 3 R42BAT OR RD C2P 4 P26BAT BK C9P 1 P22BAT BK C7P 1 C9HRN BK RD C3P 9 C27AUX RD C1P 1 C17PRR BL 47 2 C18PRLOR C47 1 C44JD WH C47 3 C43JU BK C47 4 47 5 RD C47 6 WORK LIGHTS OPTION 2308 RJ MODELS JIB ROTATE Z30N RJ MODELS Genie Z 30 20N 2 30 20 RJ 2 34 22 2 34 22 Part No 139378 126 127 September 2015 Electrical Schematic CE before serial nu
11. D E K L ES34DCT Genie ATEREX BRAND Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N Part No 139378 TERMINAL BABE TB DESCRIPTION CIRCUIT WIRES FROM CONNECTOR TO CONNECTOR FLASH BEACON 184 RD C32 1 KEYSWITCH POWER WIRES CIRCUIT FROM DESCRIPTION RDAWH TILT WH G7B 2 134 RD KSI 4 KEYSWITCH POWER 134 WH C102 181482 JUNCTION BR CB2 BK FLASH 52 BR MH BR CR4 GROUND BATGND 24 J2 052 1 162454 JUNCTION BRCB2 BRC7B 3 52 BR SP GROUND ROWHCHS 4 RDWHMH BRARERELEABE OR K cona TS 66 SP JIB ROTATE RIGHT Z30NRJ ONLY CoB 2 SP JIB ROTATE LEFT Za0NR ONLY OP AD CRI OR RD 28 4 42 640 10 OR AD L3 SWITCHED 48V R42BAT GAER UD pA TE ass 16 sueco BL BK C1B 11 a7 BL BK MH STEER RIGHT O878CW E m me 6 so BL 1 10 36 BL MH STEER LEFT on pum mem See iT SPEED 27 1 A
12. C1B ito o C49 L WIRES FROM CONNECTOR TO CONNECTOR M TERMINAL BASE TB DESCRIPTION CIRCUIT RD WH FLASH BEACON 184 RD Ca2 1 KEYSWITCH POWER P134BAT WIRES CIRCUIT FROM DESCRIPTION RD WH TILT WHC7B2 184 RD KG4 KEYSWITCH POWER 1 BK FLASH BEACON OPT 52 BR MH BR CR GROUND BATGND 287 pu WH 11 4 10 2 BR 8 2 du 52 BR BR SP GROUND BATGND brum m 35 GS de ROTATE FIGHT PI ONA RDAWH CRS WHIBI SP 48 RDAWH MH RD WH SP BRAKE RELEASE E us ROTATE LEFT 2808 RJ ONLY ORIRD CR1 ORRD 42 OR RD C49 10 OR RD L3 SWITCHED 48V PA2BAT GREK 028 8 TS 58 SP JIB DOWN 6 BL BK 1 11 37 BL BK MH STEER RIGHT CazScw pU mum 5 SP BUS M enn BLCIB 10 BLMH a Cosscc oR C405 C522 49 9 CH OFF LIMIT SPEED AD CR3 RD 27 RD SP AUXILIARY PUMP GOTAUX m pem g
13. Ts15 _ DRIVE ENABLE TOGGLE SWITCH R 5 2 i 2 3 5 5 5 iom RE 5 55 2 5 5 5 5 E 7516 __ JIB ROTATE TOGGLE SWITCH Z30NRJ ONLY i9 SIA E 9 9 o 8 5 Bo g 8 Nox 8 E l n 2 v 2 a o o 8 RJ 9 S E 2 o H1 TILT ALARM l 2 E B g ES 218 3 2 IS 2 E 3 2 55 g 5 5 g BATTERY CHARGE INDICATOR OPTION I F E S e uH T DRIVE ENABLE LED 4 La PLATFORM OVERLOAD LED mE OPTION L48 TURNTABLE TILT ALARM LED OPTION RJ ONLY 2308 RJ MODELS 35 TIME DELAY RELAY 2 SECONDS 30A R20 RESISTOR 4 7k Genie A TEREX BRAND 156 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N Part No 139378 Genie North America Phone 425 881 1800 Toll Free USA and Canada 800 536 1800 Fax 425 883 3475 Genie Scandinavia Phone 0046 3157 5154 Fax 0046 3157 5104 Genie France Phone 0033 237 260 986 Fax 0033 237 260 998 Genie Iberica Phone 0034 935 725 090 Fax 0034 935 725 080 Genie Germany Phone 0800 180 9017 Phone 0049 4221 491 821 Fax 0049 4221 491 820 Genie Austra
14. 1 TOTERMINAL BASE M 3 AND CONNECTORS ONCO FID C48 1 Dor 1 2 4 4 T551 RDH34A 145 G BK 22A 1 FD C22 8 RD 27A 145 ORIBK 15A 7 LABEL DESCRIPTION WHIRD GA a ese ee Pi EMERGENCY STOP BUTTON 698028 T TS63 KS1 KEY SWITCH gnon 2 OOO AUXILIARY TOGGLE SWITCH ey TT TS66 ac 5 855 _ FUNCTION ENABLE TOGGLE SWITCH TS66 TS63 1559 OR 14A Beren 5 6 T857 __ PLATFORM ROTATE TOGGLE SWITCH 222 1658 _ JIBBOOM UP DOWN TOGGLE SWITCH P TEES umm 5 6 1359 PLATFORM LEVEL TOGGLE SWITCH em 5 TS60 SECONDARY BOOM UP DOWN TOGGLE SWITCH _ ud TS61 PRIMARY BOOM UP DOWN TOGGLE SWITCH BK226 GN 43A 8 wi Ou 565 TS58 TS61 7657 1562 TURNTABLE ROTATE TOGGLE SWITCH 5 4 ADIBK 2A Bat RD 1A PRIMARY BOOM EXTEND RETRACT TOGGLE SWITCH __ PES 1568 JIB ROTATE TOGGLE SWITCH 230 RJ ONLY WHIBK SA 6 3 WH 4A zj T862 CIRCUIT BREAKER CONTROLS 10A ze Rig 5 o co om wem WIE T 99 a B 1999 TSe2 CH CHASSIS HARNESS prt CORP
15. 1 48 2 TILT SENSOR LI 2 BK 8 BRCB2 SWITCH PANEL d 13 2 BR 2D fs BK C49 7 BR C48 3 OR RD 42A WH BK 19C 48C C32 12 T 1 f TO TERMINAL BASE O NGO HM 3 AND CONNECTORS RD C48 1 CB2 551 po 51 1 4 22 1 RD C23 6 RD 27A OR BK 15A BK 7A 8 LABEL DESCRIPTION WH RD 6A ecce 1859 P1 EMERGENCY STOP BUTTON ROTATE ORBK C2 3 2 KSI KEY SWITCH MODELS 1 i Po Wn 1 4 5 851 AUXILIARY TOGGLE SWITCH TS66 Ou 5 TS55 FUNCTION ENABLE TOGGLE SWITCH L TS57 _ PLATFORM ROTATE TOGGLE SWITCH PR TS58 JIB BOOM UP DOWN TOGGLE SWITCH GNAWHLABA TES 2 TS59 PLATFORM LEVEL TOGGLE SWITCH 2 557 78860 SECONDARY BOOM UP DOWN TOGGLE SWITCH _BLIWH G12 D g 861 PRIMARY BOOM UP DOWN TOGGLE SWITCH BK206 GN 43A deu Qe 2 TS62 TURNTABLE ROTATE TOGGLE SWITCH RD BK 2A c 786 PRIMARY BOOM EXTEND RETRACT TOGGLE SWITCH TE TS66 JIB ROTATE TOGGLE SWITCH Z30NR ONLY 3
16. GN 17A WH BK BA 1562 6 TS60 O d 029 ads BL BK 11A RD O32 7 Part No 139378 BL 10A ES34DCU Genie ATEREX BRAND Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N 143 September 2015 _____________________ _ MM EGG N n Ground Control Box Switch Panel Wiring Diagram ANSI CSA from serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 144 145 September 2015 E Platform Control Wiring Diagram ANSI CSA from serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 September 2015 Platform Control Box Wiring Diagram ANSI CSA from serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 Service Manual PLATFORM CONTROL BOX WORK LIGHTS OPTION WH zem il ES34DCU P48LPS WH C2P 10 WH RD 7548 RELAY WORK LIGHTS OPTION EMERGENCY STOP BUTTON FUNCTION SPEED CONTROLLER PLATFORM ROTATE TOGGLE SWITCH PLATFORM LEVEL TOGGLE SWITCH SECONDARY BOOM UPDOWN TOGGLE SWITCH TURNTABLE ROTATE TOGGLE SWITCH EXTEND RETRACT TOGGLE SWITCH DRIVE ENABLE TOGGLE SWITCH JB ROTATE TOGGLE SWITGH 230 ONLY BATTERY CHARGE INDICATOR
17. Reference Examples Section Maintenance B 3 Section Repair Procedure 4 2 Section Fault Codes All charts Electronic Version the update Section Schematics Legends and schematics Click on any content or procedure in the Table of Contents to view Genie iv Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N Part No 139378 2015 Service Manual Introduction Serial Number Legend Genie gt Model 2 30 20 Serial number Z30N05 12345 Model year 2005 Manufacture date 04 12 05 Electrical schematic number ESXXXX 5 Machine unladen weight 12345 Rated work load including occupants XXX Ib XXX kg Maximum number of platfrm occupants X Maximum allowable side force Ib Maximum allowable inclination of the chassis 0 deg Maximum wind speed XX mph XX m s Maximum platform height XX ft XX m Z 30 20N Maximum platform reach XX ft XX m Z 30 20N RJ Gradeability N A Country of manufacture USA This machine complies with Terex South Dakota Inc 500 Oak Wood Road 5 1150 F3 Watertown SD 57201 USA Z 34 22N
18. i 4 6 re a ORBK EYE 21 B a o 5 5 CI4PLU 1 CAPS CI6PLDORBK _ 1 E lt BKIWH i 4 4 CaP 7 C7PBE BK M cape CBPBRBKWH C3B8 _ p UP m a ve S RD BK 4 28 AE Dow 1 C3B 1 T C3P 2 CNPBDRDBK 5 t z 1 BL BK 33 8 DOWN Tz A 1 5 8 i 1 1 Lid ug __ _G10SBU BL CIISEDBUBK mr 5 5 l EE ate 117 8 us PR m CaP 5 CSTRAWHBK C385 Lt CATRLWH 8 m T T UT 5 3 b iB E 28 imo EF 8 8 5558 5 N 129 DRIVE ENABLE LIMIT SWITCH TRAVEL ALARM BRAKE RELEASE NC COIL BRAKE RELEASE NO COIL BRAKE RELEASE PRESSURE SWITCH STEER LEFT STEER RIGHT HOUR METER P Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N AUXILIARY CONTROL RELAY Part No 139378 PLATFORM ROTATE RIGHT JIB BOOM UP PLATFORM ROTATE LEFT JIB BOOM DOWN PLATFORM LEVEL UP COIL PLATFORM LEVEL DOWN COIL BOOM EXTEND BOOM RETRACT PRIMARY BOOM UP PRIMARY BOOM DOWN SECONDARY BOOM
19. 23048 2800 psi 193 bar 17 1 BRAKES I pac MOTOR 4 5 234 23400 3200 psi 221 bar 3000 psl 3 0 090 inch 207 bar BB 229mm 200 Tow 451 7 6 cu in rev 24 0 7 i MASTER 124 5 cofrev mt X 9 CYLINDER 1 1 VT NE 1 x 1 1 Ql ME E ud FII Lit BC L BD rater 3000 pel 8 1 l 6 m AUXILIARY PRIMARY e un ips u 2 2T si se capo 55 PUMP PUMP B rx 0 5 apm 21 gpm v i i 4 i 1 n L4 1 89 L min 7 95 Limin A 1 2 4 ae RIT d Liom Be Xs Dl W li Eel 1 2000 pei 1100 psi 1800 1600 psi 1800 ps Es 5 P IJ C 207 bar B 75 8 bar 110 bar 110 bar 124 81 H 7 s jy AL LA 10 MICRON i 100 MESH X 2 986 inch 2 on A Y U K HK n stein X HYDRAULIC RESERVOIR 4 1 z Lee 22 20 1 m FUNCTION MANIFOLD _ _ 8 Genie A TEREX BRAND 116 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N Part No 139378 117 September 2015 Ele
20. es 51 BD 134A us CO 4 BK 22A BD Co3 8 RD 27A ORBK 15A 7 BKANH SA WHIRD 6A lt L yee ORBKC28 pepe SS TS63 000 fogo Were a Teque L R R E n OR 14A pone GN BK 18A GN WH 19A TS61 1857 GN BK 44A ES BLWHCI 12 5 p BK22c GN 43A 899 LAR BKG71 BD BK 2A Ou in 1 T 1 gm E E ADM 1862 65 8 T860 O 5 5 249 BL BK 11A i RD Co2 7 E AOA do ES 118 4 5 6 7 8 12 7 caz ES34DCU 8 Genie Part No 139378 Z 30 20N Z 30 20N RJ 2 34 22 2 34 22 153 September 2015 ___________________________ _ _______ _ Ground Control Box Switch Panel Wiring Diagram AS from serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 154 155 September 2015 a 91 Platform Control Box Wiring Diagram AS CE from serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 Service Manual Platform Control Box Wiring Diagram AS CE from serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 September 2015
21. MANIFOLD HARNESS 8 SWITCH PANEL BL 0A cA CONTROL RELAY OOOO TRAVEL ALARM mer ate H4 DESGENT ALARM NNMERO 1 7 H6 PLATFORM OVERLOAD Ne DESCENT ALARM WIRING 13 CONTROLLER STATUS LED 145 PLATFORM OVERLOAD LED ESSADCT U33 Genie ATEREX BRAND Part No 139378 Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N 133 September 2015 Ground Control Box Switch Panel Wiring Diagram before serial numbers Z30N10 12119 Z34N10 8857 and 23410 7774 134 135 September 2015 Platform Control Box Wiring Diagram CE before serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 Platform Control Box Wiring Diagram CE before serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 A B D E 9 22 Qu udrzro 9270 fero 136 279 NEVO 6 79 HM September 2015 4 1 9
22. OR BK j PLATFORM LEVEL z a 7 5 ag E iH Biku Pa 4 up GAP 2 y G14PLU OR 4 2 1 1 C15PLD ORIEK 1 048 8 x DOWN c EXTEND B BK A z BOOM EXTEND 1 sl ii Hd e BKIWH BOOM Eod 32 ag RETRACT 7g Aa BOOM RETRACT fd EB ts l C3P 7 C7PBE C3B7 m BKAVH E E B pr mun RD BK 4 PRIMARY 2 S A5 DOWN BOOM DOWN I jig 4 1 ez 8 up 1151 1 CIPBU RD 1 gt 2 0382 DOWN uP BL 4 SECONDARY BOOM UP g 2 BL BK gt SECONDARY 83 DOWN BOOM DOWN ud in B ay v v8 z a 8 8 58 3 up 5 10 CIOSBUBL 3 10 oF i Eas 5 1 ALARM JO 4 ELEK C3B 11 DOWN om n RIGHT 8 WHEBK TURNTABLE 8 Fs t ROTATE RIGHT E mit WH n TURNTABLE 8 LEFT a ROTATE LEFT E 289 RIGHT C3P 5 OBTRR WH BK 038 5 Li 4 Te 3 4_ gt 4 1 fo ep ge 11 a hn ceram UN EN E FIT E Cop 2 4 P ad ji WH 411
23. 21 21 B 1 Inspect the Battery te 21 B 2 Inspect the Electrical Wiring 22 B 3 Inspect the Tires Wheels and Lug Nut Torque 23 B 4 Confirm the Proper Brake Configuration 24 B 5 Check the Drive Hub Oil Level and Fastener 24 B 6 Test the Ground Control Override sss 25 B 7 Test the Platform 26 B 8 Test Drive 26 B 9 Test the Drive Speed Stowed Position 27 B 10 Test the Drive Speed Raised or Extended Position 28 B 11 Test the Alarm Package if equipped 29 B 12 Test the Turntable Rotation 2 22 4 0 30 B 13 Check the Electrical Contactors 30 B 14 Perform Hydraulic Oil 31 B 15 Test the Emergency Power System 31 Genie BRAND Part No 139378 Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N ix September 2015 EEE Table of Contents Checklist C Procedures nennen nnne nennen 33 C 1
24. SAE Dash Size Thread Size Flats tube fitting installed into Steel 4 7 16 20 2 SAE Dash Size Torque 6 9 16 18 1 4 5 37 Adj 15 ft lbs 20 3 Nm 8 3 4 16 1 ORFS Non adj 26 ft lbs 35 3 Nm ey 37 Non adj 22 ft lbs 30 Nm en 16 1 5 16 12 1 8 5 Adj Non adj 60 ft lbs 81 3 Nm 20 1 5 8 12 1 37 Adj 52 ft lbs 70 5 Nm 24 1 7 8 12 1 10 ORFS Adj 100 ft lbs 135 6 Nm 37 Adj Non adj 85 ft lbs 115 3 Nm 12 All types 135 ft lbs 183 Nm 16 All types 200 ft Ibs 271 2 Nm 20 All types 250 ft lbs 339 Nm 24 All types 305 ft lbs 413 5 Nm Genie Part No 139378 BRAND Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N Service Manual Specifications Torque Procedure Seal Lok fittings 1 Replace the O ring The O ring must be replaced anytime the seal has been broken The O ring cannot be re used if the fitting or hose end has been tightened beyond finger tight Note The O ring in Parker Seal Lok fittings and hose end are custom size O rings They are not standard size O rings They are available in the O ring field service kit Genie part number 49612 2 3 Lubricate the O ring before installation Be sure the O ring face seal is seated and retained properly Position the tube and nut squarely on the face seal end of the fitting and tighten the nut finger ti
25. Unless otherwise specified perform each procedure with the machine in the following configuration e Machine parked on a firm level surface e Key switch in the off position with the key removed e The red Emergency Stop button in the off position at both ground and platform controls e Wheels chocked e All external AC power supply disconnected from the machine e Boom in the stowed position e Turntable secured with the turntable rotation lock Part No 139378 Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N 11 September 2015 Scheduled Maintenance Procedures About This Section This section contains detailed procedures for each scheduled maintenance inspection Each procedure includes a description safety warnings and step by step instructions Symbols Legend Safety alert symbol used to alert A personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death ADANGER Indicates a imminently hazardous situation which if not avoided will result in death or serious injury AWARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION Indicates a potentially hazardous situation which if not avoided may cause minor or moderate injury Indicates a potentially hazardous situation which if not avoided
26. s e 5 ks TREL ut as gt 5 ag B g BK BK 7 gt Be x le 7X T a 52 1 011 4 WHS 248 on WHS CHa BKS aas a 2 EH 98 5 CITSCSLBKS 5 Y ES ORRD GRS 2492 CABBRIK glg 20 Y egt GRN 1 4 e 5 5 8 case OR OFFLIMTSPDINP a a BLAWH INTERLOCK 9 02946 RD WH 88 5 5 1 6 3228 WHAD 1 amp WHRD 5 1 CIPS _ CSIREV WHIBK 185 C495 WHK BEVERSE CaoFWD WH 4 WH FORWARD 4 DIODE RETURN 9 RABAT ORD ly INPUT 1 2 8 5 5 5 9 5 SEE 4 id Je Es oe 5 d poc y 4 RD RD 20 Se Ss 1 A E RR 1 5 EM 9 gi Ex ie Lv LN 55 T N 1O ES34DCU L29 DHIVE LIGHT OPTION L30 WORK LIGHTS 48V POWER RELAY CR 48V POWER RELAY FLASHING OPTION TILT SENSOR BASE CONTROL BOX GROUND AUXILIARY LIFT PUMP PRIMARY LIFT PUMP GONTAC
27. 6 CIRCUIT BREAKER CONTROLS 10A 8 5 FA DoS CIRCUIT BREAKER CONTROLS RETURN 10A 595 8 TS60 e HM HOURMETER E o BL K 11A CHASSIS HARNESS BD Ca2 7 MH MANIFOLD HARNESS SP SWITCH PANEL BL 10A CONTROL RELAY ibn 9 H3 TRAVEL ALARM 7 12 H4 DESCENT ALARM OPTION Ec E E Q Q L3 CONTROLLER STATUS LED ES34DCT Genie ATEREX BRAND Part No 139378 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N 123 September 2015 __________________________ _ __ ___ _ ___ Ground Control Box Switch Panel Wiring Diagram ANSI CSA AS before serial numbers Z30N10 12119 Z34N10 8857 and 23410 7774 124 125 September 2015 Platform Control Box Wiring Diagram ANSI CSA AS before serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 September 2015 Platform Control Box Wiring Diagram ANSI CSA AS before serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 PLATFORM CONTROL BOX in JIB WORK LIGHTS OPTION WH 45 pi cl E le P48LPS WH RD C1P 9 C47 WH RD T349 2 BAN JIE ON Z 34 22 MODE
28. C2B 12 WH RD 27D 128 TO TERMINAL BASE GRMWH 18C WH e AND RELAY BLOCK OR RD C48 2 GR WH C49 11 BK 22A GND BR cri H BR 52A CR23 RD WH C3B 3 AP2 en 448VDC pig RD LT BK RD MH HORN DRIVE LIGHTS OPTION OR RD 42D BK RD C3B 9 RD C49 1 GONTROL RELAY RD ANH 48D CR1 SECONDARY 48V POWER CR2 PRIMARY 48V POWER CR3 AUXILIARY PUMP A CR4 HORN RD BK C49 2 CR5 BRAKE RELEASE CR23 DRIVE LIGHTS OPTION OR RD 16A RELAY SOCKET SHOWN N BR 52A DESCENT ALARM WIRING TS51 1557 g September 2015 Service Manual Ground Control Box Switch Panel Wiring Diagram ANSI CSA AS before serial numbers Z30N10 12119 234N10 8857 and Z3410 7774
29. gt 62 gt w e 5 o 5 o o o o lt gt olo Blof 2 4 gt v e 65 22 ge e a m 420 570 Genie A TEREX BRAND 10 Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N Part No 139378 September 2015 Service Manual Scheduled Maintenance Procedures 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 semi annually annually and every 2 years as specified of the Maintenance inspection Report The frequency and extent of periodic examinations and tests may also depend on national regulations A WARNING Failure to perform each procedure as presented and scheduled may cause death serious injury or substantial damage Immediately tag and remove from service a damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Use only Genie approved replacement parts 44 WN 5 Machines that have been out of service for a period longer than 3 months must complete the quarterly inspection Genie BRAND Machine Configuration
30. C14PLU OR C4P 2 pamm Sr Pared are 47 C2P 3 C46JRL OR C2P 2 WH D PRA LO 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 T 1 1 1 1 1 4 1 1 1 1 1 1 1 L C15PLD OREK C4P 3 BK WH 8 C7PBE BK C3P 7 C18DEL BL RD C4P 1 C378CW BL K 1 11 365 BL 10 BRN ORGRD P24BAT WH C9P 2 RD C30FWD WH 4 WH BK C1P 5 G32JSLWHIRD C1P 6 C29J5H RD WH C1P 3 1123456789110 TS1 O 066 NO LO NC O4 NC DP1 RD WH C3P 3 R42BAT OR RD 2 4 P26BAT C9P 1 P22BAT BK C7P 1 C9HRN BK RD C3P 9 C27AUX RD C1P 1 C17PRR BL C47 2 G18PRL OR C47 1 C44JD WH C47 3 C43JU C47 4 Z30N MODELS Part No 139378 JIB ROTATE Z30N RJ MODELS Genie Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N 146 147 September 2015 ll Electrical Schematic AS CE from serial numbers Z30N10 12119
31. 1 d 1 1 I 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 8 1 2 4 PA2BATORRD 28 4 i 8 R SS 1 OSPS BRN eg net p BRN 1 1 8 8 pops sos 1 avy RDMH Viv TNA utc eee eee 5 EE OE 2 G28TTA RD BK RD K WH 8 lt lt RD 2 RD BK BAN 9 4 8 m 1 z B 8 i RD gg C3P 9 44 COHAN BK RD TY Fil BENE 116 E E a 649 1 AD C133PLABL RD lt C2B 1 a Al f 5 SOR poopar ek CAM CILPEGAWH 8 z i gs 1 8 8 Tog 4 gg FA2BAT GR WH Lag gt E d pu si 8 A Bi 5 i 5 sp e a 5 BKAD 8 8 BRN TX i BK gt 48 4 BD P2218 C10 1 BT e 81 P22BAT BK 5 cozway SOUS lt i m 3 052 1 BK 8 f Cra wies i 5 052 2 WH 8 6 5 8 aa 8 SE 1 3 58 5 _ 649 7 17809 ORRD CRS 49 2 CAgBRK Pat G182PWA GR
32. 1 Model 2 Model year 3 Sequence number 4 Serial number stamped on chassis 5 Serial label located under cover Genie BRAND Part No 139378 Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N V September 2015 Safety Rules Danger Failure to obey the instructions and safety rules in this manual and the appropriate Operator s Manual on your machine 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 MI You are trained and qualified to perform maintenance on this machine You read understand and obey e 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 Qai 1 1 1 1 vi Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N Part No 139378 September 2015 Service Manual 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 DANGER Read each procedure thoroughly This manual and the decals on the machine use signal words to identify the following Safety alert symbol
33. 2 34 22 2 34 22 Part No 139378 September 2015 9 Test the Drive Speed Stowed Position Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Proper drive functions are essential to safe machine operation The drive function should respond quickly and smoothly to operator control Drive performance should also be free of hesitation jerking and unusual noise over the entire proportionally controlled speed range Note Select a test area that is firm level and free of obstructions 1 Create start and finish lines by marking two lines on the ground 40 feet 12 2 m apart 2 Turnthe key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls Lower the boom to the stowed position 4 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the start and finish lines Genie BRAND Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N 27 Part No 139378 Checklist B Procedures Bring the machine to top drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line Continue at full speed and note the time when the machine reference point crosses the finish line Refer to Specifications Performance Specifications
34. Result The platform should remain level at all times to within x5 degrees B 8 Test the Drive Brakes Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Proper brake action is essential to safe machine operation The drive brake function should operate smoothly free of hesitation jerking and unusual noise Hydraulically released individual wheel brakes can appear to operate normally when they are actually not fully operational A WARNING Collision hazard Be sure that the machine is not in free wheel or partial free wheel configuration Refer to maintenance procedure Confirm the Proper Brake Configuration Note Select a test area that is firm level and free of obstructions Mark a test line on the ground for reference Lower the boom to the stowed position Turn the key switch to platform controls Choose point the machine i e contact patch of a tire as a visual reference for use when crossing the test line 5 Bring the machine to top drive speed before reaching the test line Release the drive joystick when your reference point on the machine crosses the test line 6 Measure the distance between the test line and your machine reference point Refer to Specifications Performance Specifications Note The brakes must be able to hold the machine on any slope it is able to climb Genie 26 Z 30 20N Z 30 20N RJ
35. s BR ae DRIVE LIGHTS eet gt lt 27190 g 52 P Ex aes 1 WH 2 11 WORK LIGHTS gt lt PAMPSWH 020 M z i Q ie Q w 85 ae T aS es 952 x lt zx cd a 8 B 1 2g TTT S 6 149 P Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N Part No 139378 September 2015 _______ __ __ Electrical Schematic AS CE from serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 150 151 September 2015 Ground Control Box Terminal Strip Wiring Diagram AS CE from serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 Service Manual September 2015 di d P w Ground Control Box Terminal Strip Wiring Diagram AS CE from serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 152 A 154 SECONDARY UP DOWN LS3 DRIVE ENABLE LS2 PRIMARY UP DOWN 151 PRIMARY EXTEND RETRACT CABLE 2 CABLE 3 CABLE 1 MANIFOLD HARNESS CHASSIS HARNESS CH B 600000 C4B 000000 C3B 000000 000000 C2B
36. BRAKE RELEASE CR23 DRIVE LIGHTS OPTION OR RD 16A ES34DCT Genie A TEREX BRAND Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N Part No 139378 REF 86 85 87A 87 RELAY SOCKET SHOWN September 2015 Service Manual Ground Control Box Switch Panel Wiring Diagram CE before serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 RD C32 1 eg a 1 RD WH I8A SENSOR aA BDWariun LI 20 RDBKCIB2 m Bk B N V BR 52A SWITCH PANEL Q V A T RD 1348 2 BL RD G2B 1 BR 52D BK C49 7 WH BK 19C 48C BR C48 3 OR RD 42A C32 12
37. C46JAL j 4 4 4 J Lors cavi B X GATJAR AD ii l EE 8 1 JOWN E 1 2 C4AJU GR cap 2 8 _ 4 GR BK cape MR 474 WH pat C478 8 1 z RIGHT Ci7PRLOR HA NE PE 5 PEN 72 CISPRR BL Hit 5 CIBPRRGRBK CITPRLGR T E af Ed Lat m ti 85 DOWN 1 a 1 CISPLDOREK EXTEND _ E b t 5 3 BKWH 4 5 SENT __ c7 _ 8 OBPBRBKWH _ 08 8 IP 2 FD F zt t DOWN Ae 1 1 1 Cs 1 092 gt up 5 4 E 5 8B i DOWN e 1 B va 4 8 CaP l0 CIOSBUBL ES T CHBBDBLEK 7 A 4 m WH n LEFT B CSTAAWHAK 7 8 C4TRLWH S LEFT a jg vel _ al a 2 gf ae 2 z aE es ee i 8 8 Basle 8 T N e A 139
38. Il Ll 3 5 455 6 Ren 37 gt aa 52 conn BR 19 4 ES ss WA P48LPS WH RD C2P 10 WH 16 4 I 1 1 I 1 1 1 1 1 T i C2P 4 RA2BATOR RD E 1 BOSE TE eB CaP 8 RD WH 1 ema 1 8 E 1 2S gt DJ ADAH x i a E H Ie nim frc ELI La E WE CPBTTARDIEK 2 RD BK WH 8 lt lt PZ3BAT WH FD i Rb B 8 lt 8 1 58 a 5 Be z 3 1 ANM NER Ed gel m COHAN KRD 6389 BF 1 E g 118 emi u a 49 1 RZ7AUX RD BURD can q J Y 5 43 1 GR WH 8 8 4 lt 5 dE tts 2 e 8 8 5 5 2 RABAT GAMH al gt ERES T 2 oo Bi i BK RD 85 8 BRN
39. SECONDARY BOOM DOWN TURNTABLE ROTATE RIGHT TURNTABLE ROTATE LEFT September 2015 LES _ _ Electrical Schematic CE before serial numbers Z30N10 12119 Z34N10 8857 and 23410 7774 130 131 September 2015 Ground Control Terminal Strip Wiring Diagram CE before serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 Service Manual Ground Control Box Terminal Strip Wiring Diagram CE before serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 132 A 184 SECONDARY UP DOWN 153 DRIVE ENABLE LS2 PRIMARY UP DOWN 151 PRIMARY EXTEND RETRACT CABLE 2 CABLE 1 MANIFOLD HARNESS MH CHASSIS HARNESS cH ci 000000 2 1 C48 C49 000000 C D E September 2015 H K
40. 180 244 230 366 280 379 380 515 30 433 406 310 420 420 569 35 474 430 583 450 610 610 827 540 691 470 637 500 678 670 908 560 759 640 718 710 962 750 1016 990 1342 840 1139 800 908 890 1206 1080 1464 1440 1952 1220 1654 1138 1120 1518 1360 1844 1820 2467 1530 2074 1260 1979 2643 2570 sats 3460 424 12 1640 2223 3000 METRIC FASTENER TORQUE CHART This chart is to be used as a guide only unless noted elsewhere in this manual Class 12 9 23 110 120 176 271 170 270 300 433 A74 4 di 0 5 ah ae i d o e er _ a ele 4 gt _ EN c lc c m INST 518 lt lt Nol Co olo E c b m 5 lt D m TE IND IND Nm 6 32 2 46 7 81 110 108 147 202 274 269 365 1 525 3 715 970 762 583 791 778 1055 682 925 909 N 24 o o o eo N ac 8 1
41. 2 34 22 Z 34 22N Part No 139378 September 2015 4 Perform 30 Day Service The 30 day maintenance procedure is a onetime procedure to be performed after the first 30 days or 40 hours of usage After this interval refer to the maintenance tables for continued scheduled maintenance 1 Perform the following maintenance procedures All Models A 5 Grease the Turntable Rotation Bearing and Rotate Gear B 3 Inspect the Tires Wheels and Lug Nut Torque D 3 Check the Turntable Rotation Bearing Bolts D 5 Replace the Hydraulic Filters Checklist A Procedures A 5 Grease the Turntable Rotation Bearing and Worm Drive Gear Genie specifications require that this procedure be performed every 100 hours of operation Perform this procedure more often if dusty conditions exist Frequent application of lubrication to the turntable bearing and rotate gear is essential to good machine performance and service life Continued use of an improperly greased bearing and gear will result in component damage 1 Locate the grease fitting on the tank side turntable cover bulkhead 2 Pump grease into the turntable rotation bearing Rotate the turntable in increments of 4 to 5 inches 10 to 13 cm at a time and repeat this step until the entire bearing has been greased 3 Locate the 2 grease fittings on top of the worm drive housing 1 grease fittings 4 Pump grease into the gear until you s
42. 8 LIFT PUMP DRIVE AUXILIARY 5 CONTACTOR CONTACTOR MM 55 m 22 21120 19 18 17 16 15 14 43 SEE 12 11110 918 7 6 5 4 31211 DETAIL A 2 GR WH 2 gt P182BAT P180LPR 5 CONTACTOR 30 RELAY 85 GR WH 4CR3 C19LPE BR E GR WH 2 2 C49 5 C31REV DEJIAIL A CR20 049 4 C30FWD WH RELAY SOCKET WIRING WIRE INSERTION SIDE SHOWN 48 7 C178C8L 049 9 04015 OR 049 8 C12FTS gt CIRCUIT CHANGE P182BAT BEFORE SERIAL NUMBERS 48 3 OIGND BR Z30N Z30N10 12120 734 DC 28410 7774 Z34N Z34N10 8858 048 2 PA2BAT OR RD C180LPR AFTER SERIAL NUMBERS ES34DCU 230 RJ Z30N10 12119 48 1 P182BAT RD 234 DC 23410 7773 234 234 10 8857 Genie ATEREX BRAND Part No 139378 Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N 105 September 2015 LSS Drive Contactor Panel Wiring Diagram 106 September 2015 Manifold and Limit Switch Wiring Diagram 107 Service Manual September 2015 lt 4 Manifold and Limit Switch Wiring Diagram A B C D E F G H K
43. BOOM DOWN 8 41 v8 Bv X DESCENT ALARM C PA0 CIOSBUBL cao i T 11 _ C3 11 i 1 RIGHT WHIEK i TURNTABLE q 4 ie ROTATE RIGHT 54 47 WH 5 4 TURNTABLE LEFT ROTATE LEFT 85 AB B 5 CSTRAWHIBK C385 g 4 C amp TRL WH ce J 55 TE 5 53 8 T 8 2 5 558 55 N September 2015 52 222 Electrical Schematic ANSI CSA AS before serial numbers Z30N10 12119 Z34N10 8857 and 23410 7774 120 121 September 2015 Ground Control Box Terminal Strip Wiring Diagram ANSI CSA AS before serial numbers Z3010 12119 Z34N10 8857 and Z3410 7774 Service Manual September 2015 Ground Control Box Terminal Strip Wiring Diagram ANSI CSA AS before serial numbers Z3010 12119 Z34N10 8857 and Z3410 7774 122 A B C52 154 SECONDARY UP DOWN 133 ENABLE Ct 152 PRIMARY o0 UP DOWN o o C10 51 PRIMARY o EXTEND RETRACT CABLE 2 C7B C4B 000000 CABLE 3 000000 C3B 000000 C2B 000000 1 1 MANIFOLD HARNESS MH C48 CHASSIS HARNESS CH C49 000000
44. DRIVE ENABLE LIMIT SWITCH TRAVEL ALARM BRAKE RELEASE N C VALVE BRAKE RELEASE VALVE BRAKE PRESSURE SWITCH STEER LEFT STEER RIGHT HOUR METER P Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N AUXILIARY PUMP Part No 139378 PLATFORM ROTATE RIGHT PLATFORM ROTATE LEFT PLATFORM LEVEL UP PLATFORM LEVEL DOWN BEGONDARY BOOM UP TURNTABLE ROTATE RIGHT TURNTABLE ROTATE LEFT September 2015 __ Electrical Schematic ANSI CSA from serial numbers Z30N10 12119 Z34N10 8857 and 23410 7774 140 141 September 2015 nee a Ground Control Box Terminal Strip Wiring Diagram ANSI CSA from serial numbers Z30N10 12119 Z34N10 8857 and 23410 7774 Service Manual Ground Control Box Terminal Strip Wiring Diagram ANSI CSA from serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 142 154 SECONDARY UP DOWN 153 DRIVE ENABLE LS2 PRIMARY UP DOWN 151 PRIMARY EXTEND RETRACT CABLE 2 CABLE 3 1 MANIFOLD HARNESS MH B C11 C4B 000000 C3B 000000 000000 000000 Ooooooo yo C D E September 2015 ___ TERMINAL BASE H
45. es Platform Controls 48 Locate the diode between the black red wire from the boom function speed controller and the white red wire Disconnect the white red wire from the diode on the black red wire Connect the negative lead from a multimeter set to measure amperage to the wire connector of the white red wire Connect the positive lead of the multimeter to the diode on the black red wire Turn the boom function speed controller to the creep position Set the threshold Press down the foot switch and move the primary boom toggle switch to the up position Adjust the amperage to 0 28A Turn the threshold trimpot adjustment screw clockwise to increase the amperage or counterclockwise to decrease the amperage Turn the boom function speed controller to the 9 position Set the max out Press down the foot switch and move the primary boom toggle switch to the down position Adjust the amperage to 0 65A Turn the max out trimpot adjustment screw clockwise to increase the amperage or counterclockwise to decrease the amperage Start a timer and simultaneously press down the foot switch and move the primary boom toggle switch in the down direction Note how long it takes to reach 0 65A 10 11 September 2015 Set the ramp rate Turn the ramp rate trimpot to obtain a 2 second delay from 0 to 0 65A Turn the trimpot clockwise to increase the time or counterclockwise to decrease the time Disconnect the leads from the mu
46. 5 5 SHOWN WITH EXTENDED IPS EF 8 8 GE ETT 85 zu a ME gt EU gt 28 5 E 8 a m E BK 7 18 14 WH7 Jr 85 28 8 65 8 59 5 8 4 18 WIRES 8 3 3 5 HE JE AE JF 2 E i eK m 6 6 aja 22 mim S ar 858 CABLE 7 2 2 WH B C SERVICE HORN Ls2 d E 5 5 4 wu TILT SENSOR PRIMARY BOOM 5 E 8 B 39 g mS 2 E 8 gu 56 5 Qa a E za amp 8 25 o9 m PIN WIRES 52 zs g 2 ds H a5 55 1 RD 3 3 5 2 gge SOE gae Soe A a E amas Er CJ Q Q 4 WH E ee BRAKE PRESSURE SWITCH Br Pe 4 gt 183 n 1 1 E 1 Q C Q CJ I I 1 1 1 1 1 1 1 1 1 1 1 1 1 4 BRAKE RELEASE N C VALVE SHOWN WITH BOOM ROTATED PIN WIRES 6 E PAST EITHER NON STEER WHEEL 1 m o 9 9 GO 5 E WES ZN M f WH 5 21 22 BR 5 pem 3 BK 2 CABLES 4 WH 5 2 134 BRAKE RELEASE VALVE SECONDARY BOOM LIMIT SWITCH JIB MANIFOLD WITH JIB ROTATE OPTION 230 RJ ONLY E JIB PLATFORM ROTATE MANIFOLD C52 TOP VIEW JIB CABLE TO PLATFORM BOX TOP VIEW JIB CABLE TO PLATFORM BOX 13 24 A oA
47. 9 Disconnect the battery packs from the cylinder back and secure it from moving 21 Tag disconnect and plug the extension 10 Remove all the hose and cable clamps from cylinder hydraulic hoses Cap the fittings on the underside of the primary boom and at the the cylinder pivot end of the primary boom PL A WARNING Bodily injury hazard Spraying 11 Attach a lifting strap of ample capacity from an hydraulic oil can penetrate and overhead 5 ton 5000 kg crane to the primary burn skin Loosen hydraulic boom for support connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray ________________ Part No 139378 Z 30 20N Z 30 20N RJ Z 34 22 2 34 22 61 Primary Boom Components 22 Attach a lifting strap from an overhead crane 23 24 A WARNING 25 26 27 to the primary boom lift cylinder Place 2x 4 x 18 inch 5 x 10 x 46 cm support blocks under the cylinder across the secondary boom Remove the pin retaining fastener from the primary boom lift cylinder rod end pivot pin Use a soft metal drift to remove the pin Crushing hazard The primary boom lift cylinder could become unbalanced and fall if not properly supported by the lifting device Lower the rod end of the primary boom lift cylinder onto support blocks Protect the cylinder rod from damage Remove the pin retaining fastener from the pr
48. Eg gs i N C VALVE ES ag BRAKE RELEASE lt T 1 VALVE P es PRESSURE z SWITCH N E CS SCCBL BL Gl 4 Q d i omn Gi 4 STEER RIGHT e N N si N Ei es t 12 11 5 vs N E WHIBK H 2 HOURMETER Z gt ic OZ7AUXRD RD AUX 9 2 8 e e 5 Pza 5 s e e g 9 N 1 NE ENT 1 3 t 5 d pete 2 24 55 m RD CAG 8 8 2 5 i im 8 Q z ES 5 we 5 1 x n gt GRWH a N 1 1 GR WH 8 COMFV 7 WHAD eje 4 PROPORTIONAL T CONTROL VALVE PA E g as 9 E z E i 505 9 8528 pene em spe 1 RIGHT 1 1 E x 1 1 N go ub 8 LET o i 52 5 4 m BR OR BK 628
49. HORN 7 RELAY i i BK 55 HORN oe RET P22LS C104 A LS1EXT RET Be e 125K WH sc 1 052 1 C114 WHS 7 052 2 WHS 11 3 6 LSz PRI UP DWN 877 184 8 UP DWN 3 NS 0497 0178081 BK n CHASSIS GROUND ERE e 15 C49 2 BRAKE RELEASE amp 8 RELAY 5 onn PRI CIB2PWR GAY 47 DRIVE GONTACTOR 8 E 3 m OFF LIMT SPD 5 g 1 3 Eats g z 4 c1P3 C28J8H CIES 5493 POT 16 P E x 1 58 5 5 3218 WH RD WHIRD POT LOWS 44 E 508 a CIPS CSIREV WHISK 018 5 C495 WH EK REVERSE 4 C30FWD WH 1 4 WH FORWARD oz 5 1 DIODE RETURN 9 5 8 PA2BAT OFVAD 48V INPUTS 5 d 5 8 i Me E 8 8 BK 2 lt B p z E d 8 2 i e PRIMARY 95 LIFT PUMP 8 E 1 AUXILIARY LIFT PUMP 5 5 5 ote 3 4 1 RD RD 20 o D d ETE EL E A sili yg vi NE gt bl a 15 E karl
50. Hydraulic Component Specifications 5 Manifold Component rnnn nnne enne 5 Machine Torque 6 Hydraulic Hose and Fitting Torque 7 Torque Procedure etta tite 8 SAE and Metric Fasteners Torque 10 Genie viii Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N Part 139378 September 2015 __ ____ ________ _ Table of Contents M 11 Pre Delivery Preparation 14 Maintenance Inspection 16 Checklist Procedures 17 1 Inspect Manuals 5 17 2 Perform Pre operation 00011 18 A 3 Perom FUNCION Tests iced pend rep ira ads 18 4 Perform 30 Day 22 11 2 1 00100 0 19 5 Grease the Turntable Rotation Bearing Worm Drive 19 6 Replace the Drive Hub 00 0 20 Checklist B Procedures
51. MAIN PUMP 8 Ci79DPR OR N m peo oYOr AD S 2 14 d E ES 5 d 5 i 49 9 gt OFFAMTSPDINP E 83 BLAWH INTERLOCK 4 85 Xr C493 RDWH POLH 6 5 CIP 8 C20JSH _ C1B 3 m mes 5 i CiP 6 032181 WH RD C1B 8 C498 em 1 C495 WHBK ch P 1 5 WHIBK E 2 i om WH C B4 0494 5 gt DIODE RETURN JJ z E 5 5 FA2PWR ORRD 48 INPUT _ Pi pm 2 Leg 1 t 2 7 BK BATTERY fh 8 mos 1 anan pr A 8854 H Ti Hi et eas L PRIMARY 44 ads gt 8 1 4 LIFT PUMP 8 5 RENS HH TW XILIARY ERE ae 1 LET PUMP SS 2 e 8 55 RD 20 HH 5 C48 1 2 RD THE 8 S E al a F Dee EE N gt e N Part No 139378 Genie Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N 148 Service Manual Electrical Schematic AS CE C29JSH RD WH 632161 WH RD WH BK C3S0FWD WH from serial
52. Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications 1 disconnect and plug the hydraulic hoses from the turntable rotation motor Cap the fittings on the motor AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 2 Remove the turntable rotation motor mounting bolts Remove the motor from the machine Qai 1 h A 90 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N Part No 139378 September 2015 Service Manual 9 1 Hub and Bearings 2WD Models How to Remove the Hub and Bearings 1 Loosen the wheel lug nuts Do not remove them 2 Block the non steer wheels and place a lifting jack under the steer axle 3 Raise the machine Place blocks under the drive chassis for support 4 Remove the lug nuts Remove the tire and wheel assembly 5 Remove the dust cap cotter and castle nut Note Always use a new cotter pin when installing a castle nut 6 Pullthe hub off the yoke spindle The washer and outer bearing should fall loose from the hub 7 Place the hub on a flat surface and gently pry the grease seal out
53. Solenoid operated 3 position 4 way proportional directional valve Genie BRAND Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N HH M4 2 position 2 way solenoid valve 101 September 2015 1 Limit Switch Location Legend LS1 152 NN RM Nd LS4 Z 30 20N Z 30 20N RJ LS1 LS2 ak NN e 7 NN EE p c CREE al NN C ja LS4 7 34 22 Z 34 22N 2 fiy 2 Genie 102 Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N Part 139378 September 2015 Power Cable Wiring Diagram 103 September 2015 Power Cable Wiring Diagram A B C D E F G H LEFT SIDE AMMETER 1 BATTERY PACK BK 10 uni cs NE WH 10 _ s 2 x CHARGER PRIMARY LIFT
54. WORK LIGHTS OPTION ______ ESS4DCT JIB ROTATE WORK LIGHTS OPTION Z30N RJ ONLY 2301 RJ MODELS 137 September 2015 _______________________________________________________________________________________________ Electrical Schematic ANSI CSA from serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 September 2015 Service Manual Electrical Schematic ANSI CSA from serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 29 5 RD WH T N Ut 19 1 FERFE i i 489 FEE i 3 81212 2 51818 8 55 1 1 1 i 1 1 1 1 i 1 i 1 if 1 1 1 1 1 1 1 1 M 1 1 D Wey fo ni 32 5 C2P 12 AD 16 4 2 eps 4 5 1 lg CUM
55. Z 34 22N 41 Part No 139378 n 2 4 Checklist E Procedures 4 Openthe valve on the hydraulic tank and 9 completely drain the oil into a suitable container 10 Bodily injury hazard Beware of CAUTION hot oil Contact with hot oil may H cause severe burns 12 5 disconnect and plug the hydraulic hoses from the hydraulic tank return filter housing Cap the fittings on the filter housing A WARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to 13 squirt or spray 44 Bodily injury hazard Beware of CAUTION hot oil Contact with hot oil may cause severe burns 15 6 Remove the hydraulic tank mounting fasteners Remove the hydraulic tank from the 16 machine 7 Remove the tank lid retaining fasteners and remove the lid and return filter assembly from the tank 8 Remove the suction strainer from the hydraulic tank and clean it using a mild solvent Genie 42 Z 30 20N Z 30 20N RJ 2 34 22 2 34 22 September 2015 Rinse out the inside of the tank with a mild solvent Install the suction strainer into the tank Install the lid and return filer assembly onto the hydraulic tank Install the hydraulic
56. disconnect and plug the primary boom lift cylinder hydraulic hoses Cap the fittings on 6 Place a block of wood between the the cylinder counterweight plate on the leveling link and MM the cross member of the upper secondary AWARNING Bodily injury hazard Spraying boom Carefully lower the secondary boom hydraulic oil can penetrate and onto the block burn skin Loosen hydraulic connections very slowly to allow AWARNING Crushing hazard Keep hands the oil pressure to dissipate away from the block and all gradually Do not allow oil to moving parts when lowering the squirt or spray secondary boom onto the block 13 Support the barrel end of the primary boom lift 7 Remove the pin retaining fasteners from the cylinder with straps or ropes to restrict it from primary boom lift cylinder rod end pivot pin swinging freely 14 Remove the pin retaining fastener from the Crushing hazard The primary primary boom lift cylinder barrel end pivot pin A WARNING boom lift cylinder could become Do not remove the pivot pin unbalanced and fall if not properly supported by the lifting device 8 Lower the rod end of the cylinder onto the blocks that were placed on the upper secondary boom Ganie 64 Z 30 20N 2 30 20 RJ 2 34 22 Z 34 22N Part No 139378 September 2015 Service Manual 15 Place a rod through the barrel end pivot pin and twist to remove the pin AWARNING Crushing haza
57. 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 1 1 1 1 12 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N Part No 139378 September 2015 Service Manual Scheduled Maintenance Procedures Maintenance Symbols Legend Note The following symbols have been used in this manual to help communicate the intent of the instructions When one or more of the symbols appear at the beginning of a maintenance procedure it conveys the meaning below Indicates that tools will be required to perform this procedure Indicates that new parts will be required to perform this procedure Indicates that dealer service will be required to perform this procedure Indicates that a cold motor or pump will be required to perform this procedure Pre delivery Preparation Report The pre delivery preparation report contains checklists for each type of scheduled inspection Make copies for each inspection Store completed forms as required Maintenance Schedule The Scheduled Maintenance Procedures section and the Maintenance Inspection Report have been divided into subsections Use the following chart to determine which group s of procedures are required to perform a scheduled inspection Inspection Checklist Daily or every 8 hours A Quarterly or every 250 hou
58. normally open normally closed normally open plug or flame ignitor 1 1 1 1 1 100 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N Part No 139378 September 2015 Service Manual Hydraulic Symbols Legend 0 037 incn 0 94 mm Orifice with size Check valve X Shut off valve n Brake Pump fixed displacement Pump bi directional variable displacement Motor bi directional Motor 2 speed bi directional Double acting cylinder lt gt 9 Filter with bypass relief Pump prime mover engine or motor Relief valve with pressure Shuttle valve 2 position 3 way Xr Priority flow regulator valve Differential sensing valve Solenoid operated valve setting proportional valve WEERA TERN 50 50 cH Te LT Directional mechanically activated Flow divider combiner valve Pilot operated 3 position 3 way shuttle valve Solenoid operated 2 position 3 way directional valve Counterbalance valve with pressure and pilot ratio Part No 139378 X Solenoid operated 3 position 4 way directional valve
59. terminal on the motor controller Part No 139378 Genie BRAND Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N 97 September 2015 ______ ___ __ ___________ _ _______ __ Fault Codes Fault Code Chart Fault Code Programmer Condition Possible Causes Solution Diagnostic Display 34 MISSING Machine will not drive Motor controller does Consult Genie Product CONTACTOR not detect the main Support contactor PR1 or brake release relay CR5 MAIN CONT DNC Machine will not drive Main contactor PR1 or Consult Genie Product brake release relay Support CR5 did not close OR open in org red wire to PR1 and or CR5 OR main contactor and or brake release relay is defective 41 LOW BATTERY Machine will not drive Battery supply voltage Completely charge to motor controller less batteries OR check than 32V DC battery cable condition OR check for corrosion or loose connections at battery terminals and motor controller 42 OVERVOLTAGE Machine will not drive Battery supply voltage Be sure the battery to motor controller charger is more than 55V DC OR disconnected OR machine is being check for loose battery operated with the cables or poor battery charger connections plugged in 43 THERMAL Machine will not drive Machine being Operate machine operated outside of within specified temperature range of temperat
60. 1 E ice LV INST 1 5 5 9 42 28 N m 139378 Genie Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N 4 ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED B BHOWN WITH BOOM ROTATED PAST EITHER NON STEER WHEEL gt ADD 040 ONLY IF UNIT HAS L4 AND 148 gt BWITCH SHOWN WITH BOOM EXTENDED 8 128 Service Manual September 2015 Electrical Schematic CE before serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 C28JSH C28J8H G82J5L Ga2JSL WH RD 1 WH BK CS0FWD WH WH BK CS0FWD WH N 5 C7P 3 BATGND CTB 3 BATGND m i CISDELBLFD CiSDELBL RD C64 WHs X BANS cae El a 1 0 12 Ci2FTS BLWH CsB 12 m 12 68 3 5 ADS C4P CI DEORD CISDE OR RD ORD RD WH BE 4 oS 282 8
61. 12 _ CI2FTS BLWH gs ADS CIODEQRAD _ 048 4 E CieDE la RD WH 5 2 bz 5 5 e ft g 55 ss i ut 58 Je 4 i pepesesteseesese PS1 in 1 10 COSSCCBL 1 10 BL 5 4 378 P BL K ni 5 5 1 E 1 3 3 al E BL 1 3 44 3 BER OB le vi 282 s SIS el 58 5 BOOT et 7 4 n ey p 8 EET S Bii z E KES I 3 mm T 7 pp ea T mu 83 5 Loe amp OZ7AUX RD oe 4 5 g s 1 alo 2 CAP 7 CIBLPE C4B 7 gt ze ciaeo x 4 6 WHAD a E WHRD eje 2 z IEEE 1 8 z 5 1 888 9 4 4 1 LL RIGHT 1 Eas z LEFT bo 4 sr A Ha 54 gt gt omunnonpk ER 8
62. 18 48V DC _ OUTPUT m o m lt eS 8228 o 3 2 5 5 2 1 9 10 d 14 16 2 17 20 5 4 4 R42BAT OR RD PR1 DRIVE CONTACTOR UGA TOP VIEW SEPEX CONTROLLER CR24 1 1 M B F2 18 B 0 DIODE LII SCHEMATIC CONTROLLER ra o BK BATTERY INDICATOR LED R42BAT RD 6 1 LED 15 RED DURING PHASES 1 AND P BULK CHARGE 20 BATTERY CHARGED R42BAT RD R42BAT RD 2 LED IS YELLOW DURING PHASES U AND 12 80 BATTERY CHARGED 3 LED IS GREEN AT THE END OF CHARGE 100 BATTERY CHARGED 4 LED FLASHES GREEN DURING CYCLE EQUALIZATION 5 LED IS OFF WHEN THE CHARGER IS NOT POWERED 6 LED FLASHES RED INDICATES DEFECT FAULT f INTERLOCK RELAY N O 10 CONTACT Q Q 1 CHARGER NOT CONNECTED TO BATTERY OR MAIN SUPPLY CONTACT OPEN 2 CHARGER CONNECTED TO BATTERY CONTACT CLOSED 7 3 CHARGER CONNECTED TO BATTERY AND MAIN SUPPLY CONTACT OPEN tr t m n c tr Oc 5 gt e ghia S ES34BEAB o 558 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 87654321 8 SEPEX CONTROLLER WIRING DIAGRAM Genie A TEREX BRAND 112 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N Part No 139378
63. 20N RJ 2 34 22 Z 34 22N 17 Part No 139378 Service Manual September 2015 Checklist A Procedures A 2 Perform Pre operation Inspection Genie specifications require that this procedure be performed every 8 hours or daily whichever comes first Completing a Pre operation Inspection is essential to safe machine operation The Pre operation Inspection is a visual inspection performed by the operator prior to each work shift The inspection is designed to discover if anything is apparently wrong with a machine before the operator performs the function tests The Pre operation Inspection also serves to determine if routine maintenance procedures are required Complete information to perform this procedure is available in the appropriate operator s manual Refer to the Operator s Manual on your machine A 3 Perform Function Tests Genie specifications require that this procedure be performed every 8 hours or daily whichever comes first Completing the function tests is essential to safe machine operation Function tests are designed to discover any malfunctions before the machine is put into service A malfunctioning machine must never be used If malfunctions are discovered the machine must be tagged and removed from service Complete information to perform this procedure is available in the appropriate operator s manual Refer to the Operator s Manual on your machine Genie 18 Z 30 20N Z 30 20N RJ
64. 3 Tagand disconnect the hydraulic hoses to the slave cylinder at the union and connect them together with a connector Cap the fittings on the cylinder hoses AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 4 Remove the external snap rings from the rod end pivot pin Do not remove the pin 5 Remove the external snap rings from the barrel end pivot pin 6 Place a block of wood under the barrel of the slave cylinder for support 7 Usea soft metal drift to remove the rod end pivot pin A WARNING Crushing hazard The platform could fall if not properly supported 8 Use a soft metal drift to remove the barrel end pivot pin 9 Carefully pull the cylinder with hydraulic hoses out of the boom How to Bleed the Slave Cylinder 1 Raise the jib boom to a horizontal position 2 Movethe platform level toggle switch up and down through two platform leveling cycles to remove any air that might be in the system Genie BRAND Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N 49 Part No 139378 September 2015 Platform Components 2 2 Platform Rotator How to Remove the Platform Rotator Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All
65. 5 5 4 p s 1 2 BL 18 1 i C1P 10 p BL 5 1 OBPSCWELEK CiB H BLEK F 1 1 a 1 t d EO o 2 E 8 1 1 fad EM 5 8 15 B C27AUX RD Hi T fT g E E d 4 5 8 2 5 Nou og a 4 5 l y 27 RD 0491 ate 4 i gt M ia 1 5 WH 9 7 C4B 7 CI9LPE g G3P 6 GEMFV WH RD 098 4 MEE WHIRD eje 5 5 PAR z i 582 5 w 5835 4 41 1 4 4 o RIGHT k 1 1 1 Bz 98 1 1 1 1 rever EET uii Ncque d PETERE 5 CAMDWH P 3 CITPRLOR 121 bp 15 1 C47 18 BL A E 1 4 8 M CI7PRLGR T x
66. 9 T 55 OR OFFLIMTSPDINP g ij 3 1 INTERLOCK 2 2 FID WH CBS RDWH POTH ig 8 3 Iss CIP 8 WHRD cus i POTLOWS CIPS CAREV WHIBK REVERSE q CB0FWD WH 4 WH FORWARD JE 1 x DIODE RETURN 9 AE 5 FA25ATORIRO INPUTS 8 a El 5 2 2 3 amp 5 8 4 8 D Lo E EE mE 5948 d a E Po ove Li Gy 8 pre bas 5 48 1 182 RD RD 20 T cen eet istos ee E FENN RENN EN 115 4 NIE LENS INO Ex 28 T N e lt ESs4DCT 128 LIGHT OPTION L30 WORK LIGHTS OPTION 48V POWER RELAY CR2 48V POWER RELAY FLASHING BEACON OPTION TILT SENSOR BASE CONTROL BOX GROUND AUXILIARY LIFT PUMP PRIMARY LIFT PUMP CONTACTOR RELAY PRIMARY LIFT PUMP PR2 HORN RELAY HORN LS1 EXT RET L82 PRI UP DWN LS4 SEC UP DWN CHASSIS GROUND BRAKE RELEASE RELAY PRI DRIVE CONTACTOR PRIMARY LIFT PUMP AUXILIARY LIFT PUMP NOTES 1 ALLLIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT NOTED gt SWITCH SHOWN WITH BOOM EXTENDED gt SWITCH SHO
67. 949 2 12 4 5 87 8 B 10 L4 LABEL DESCRIPTION 2 EMERGENCY STOP BUTTON HORN BUTTON DPI DRIVE CONTROLLER BP1 BOOM FUNCTION SPEED CONTROLLER T E AUXILIARY TOGGLE SWITCH PLATFORM ROTATE TOGGLE BWITCH JI BOOM UP DOWN TOGGLE SWITCH PLATFORM LEVEL TOGGLE SWITCH SECONDARY BOOM UP DOWN TOGGLE SWITCH 8 g gle ego gla ele ale __ PRIMARY BOOM UP DOWN TOGGLE SWITCH 9 5 e mg 9 e 9 e 9 2 9 9 7842 TURNTABLE ROTATE TOGGLE SWITCH gt E 8 5 8 5 8 g 5 8 gT 5 e 5 8 e 3 19 5 i E 9 o d ds B 8 8 _ EXTENDRETRACT TOGGLE SWITCH 5 ee 5 2 8 8 n 2 2 E 5 x i B a 2 2 5 gt E 1815 DRIVE ENABLE TOGGLE SWITCH 5 2 5 218 a 9 go a p mg o gp a JIB ROTATE TOGGLE SWITCH 2308 RJ ONLY 8 5 z a 8 B B 9 2 5 g 5 5 m E 5 2 TILT ALARM 3 8 19 8 2 5 g 8 8 5 8 x FEE BCI BATTERY CHARGE INDICATOR OPTION 8 2 le 8 9 e gig 2 2 9 8 gt 9 Li DRIVE ENABLE LED b 8 9 19 o 9 9 8 R g f 75 om 9 B P 8 T a 14 PLATFORM OVERLOAD LED 15 4 4 5 148 TURNTABLE TILT ALARM LED OPTION RELAY N O
68. OPTION TURNTABLE TILT ALARM LED OSA OPTION DRIVE CONTROLLER LABEL DESCRIPTION En GMs DPI TSi 157 1510 7811 st 1815 1516 H1 148 2 C7B 9 132 BL WH C1P 12 C28TTA RD BK 2 P23BAT WH C7P 2 C12FTS BL WH C3P 12 Ci6DRE OR RD C4P 4 5 WH BK 5 CATRL WH 4 ON 2 34 22 MODELS THIS LOCATION IS USED FOR 2 gt T849 WORK LIGHT OPTION 11580 C3P 11 gt TURNTABLE TILT ALARM LED OPTION NOTES C10SBU BL C3P 10 WH RD C3P 6 WH RD CR45 86 9 som P26BAT AD P2 IS 6do I LE C18PRR GRIBK C4P 6 C17PRL GR C4P 5 L _ 4 WORK LIGHTS OPTION bol D77 Y 1512 RO LO u p TS10 D71 BP1 RD BK TS11 C43JU GR C2P 5 G19LPE GR WH C4P 7 073 C44JD GR BK C2P 6 C2PBD RD BK 2 C1PBU RD 1 4 4 4
69. PUMP 1 Di AN BK 4 3 p D1 cL E 5 2 o 5 4 AP2 a5 BK 2 lt 3 DIODES 100A 9 DRIVE CONTACTOR No F2 PRI 100A AUXILIARY LIFT G PUMP CONTACTOR PRIMARY LIFT PUMP CONTACTOR PR2 CURTIS SEPEX 6 MOTOR CONTROLLER NOTE WIRE GAUGE NOTED IN PAENTHESES AFTER WIRE COLOR RD 10 RD 10 7 BK 2 1 7 7 F2 1 Fi BK 2 BK 2 Or ES34DCN Al A2 8 RD 10 LEFT SIDE RIGHT SIDE DRIVE MOTOR DRIVE MOTOR Genie A TEREX BRAND 104 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N Part No 139378 AUXILIARY LIFT PUMP L RIGHT SIDE BATTERY PACK September 2015 Service Manual 4 Drive Contactor Panel Wiring Diagram C D E F G H J K L M 049 1 R27AUX RD C49 11 19 R WH C49 6 C32J8L WH RD C49 8 C29J8H RD WH 49 2 CASBRK RD BK 49 10 RA2BAT OR RD 2 OR RD 2820 10 AN LJ CURTIS SEPEX MOTOR CONTROLLER OR RD OR RD 55 P j PRIMARY PR1
70. RJ Z 34 22 Z 34 22N Part No 139378 September 2015 Service Manual 6 1 Auxiliary and Function Pump How to Remove the Auxiliary Pump or Function Pump Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications 1 Tag and disconnect the cables from the auxiliary pump A WARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 2 Closethe hydraulic shutoff valve located at the hydraulic tank Component damage hazard The engine must not be started with the hydraulic tank shut off valves in the closed position or component damage will occur If the tank valves are closed remove the key from the key switch and tag the machine to inform personnel of the condition Hydraulic Pump 3 Tag disconnect and plug the hydraulic hoses from the pump Cap the fittings on the pump A WARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 4 Remove the pump mounting bolts from the pump Carefully remove the pump from the electric motor Component da
71. TO TERMINAL BASE Boami GR WH 19C 29 AND RELAY BLOCK OR RD C48 2 GR WH C49 11 BK 22A aus 1 BR 2 H H BR 52A CR23 RD WH C3B 3 a ase Fig RD gt BK RD MH HORN DRIVE LIGHTS OPTION OR RD 42D BK RD C3B 9 RD C49 1 RD WH 48D CONTROL RELAY I D SECONDARY 48V POWER PRIMARY 48 POWER ons AUXILIARY PUMP CR5 BRAKE RELEASE OR RD 16A Genie Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N 139378 CR23 DRIVE LIGHTS OPTION REF 86 85 87 87 RELAY SOCKET SHOWN B C BR 52A O P1 ONCO ONCO TS66 TS63 OR TS58 TS61 O TS60 TS55 9 O DESCENT ALARM WIRING D E TILT SENSOR RD BD AWH iSAD 20 mDEKCIB2 9 L3 BR 52D T T BK C49 7 BR CA8 3 OR RD 42A LABEL DESCRIPTION P1 EMERGENCY STOP BUTTON KSI KEY SWITCH TS51 AUXILIARY TOGGLE SWITCH 855 FUNCTION ENABLE TOGGLE SWITCH 1557 PLATFORM ROTATE TOGGLE SWITCH JIB BOOM UP DOWN TOGGLE SWITCH 1558 PLATFORM LEVEL TOGGLE SWITCH SECONDARY BOOM UF DOWN TOGGLE SWI
72. Z34N10 8857 and Z3410 7774 C28JSH RD WH September 2015 Electrical Schematic AS CE from serial numbers Z30N10 12119 Z34N10 8857 an Service Manual 2 S 8 5 amp 8 BBE za 8 i g E E E amp 8 888 T 1 n ji Y i 1 1 1 1 1 T 4 98 281 FOOT SWITCH a 2 4 lt RA2PWR 2 4 2 j amp 5 5 U35 TIME DELAY 8 5 8 a 8 En m T 5 Y Y CR RELAY 3 B ERN 48V DC POWER R
73. at the platform controls cannot return the boom to the stowed position 1 Pushin the red Emergency Stop button at the platform controls to the off position 2 Turnthe key switch to ground controls and pull out the red Emergency Stop button to the on position 3 Operate each boom function through a partial cycle at the ground controls Result All boom functions should operate Genie BRAND Part No 139378 Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N 25 Service Manual September 2015 Checklist B Procedures B 7 Test the Platform Self leveling Note Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Automatic platform self leveling throughout the full cycle of boom raising and lowering is essential for safe machine operation The platform is maintained level by the platform leveling slave cylinder which is controlled by the platform leveling master cylinder located at the base of the primary boom A platform self leveling failure creates an unsafe working condition for platform and ground personnel 1 Turnthe key switch to ground controls and pull out the red Emergency Stop button to the on position at both the ground and platform controls 2 Lower the boom to the stowed position Adjust the platform to a level position using the platform leveling toggle switch 4 Raise and lower the primary boom through a full cycle
74. can penetrate and 13 Open the platform control box DR ih Loosen De 14 disconnect each wire from the cables Cee elie VETY SOWY TO ATOW in the platform control box the oil pressure to dissipate gradually Do not allow oil to 15 Pull all the cables out of the platform control squirt or spray box 6 Remove the upper cable track mounting 16 Remove the front counterweight cover fasteners from the platform end of the boom 17 Remove the extension boom drive limit switch 7 Remove the cable track mounting fasteners a ihe rad boom at the pivot then remove the cable track from the boom Sto and lay it flat on the ground 18 Tag disconnect and plug the hydraulic hoses from the jib boom platform rotate manifold Component damage hazard The boom cable track can be 19 Pull all the electrical cables and hydraulic damaged if it is twisted hoses out of the plastic cable track Then pull all the electrical cables and hydraulic hoses Component damage hazard out through the boom rest pad Hoses can be damaged if they Component damage hazard Bre kinked OF pinched Hoses can be damaged if they 8 Raise the secondary boom until the primary are kinked or pinched boom lift cylinder rod end pivot pin is accessible above the mid pivot weldment 29 Remove pin retaining faster irom we master cylinder rod end pivot pin Use a soft Turn the machine off metal drift to remove the pivot pin Pull the
75. connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications 1 Remove the platform 2 Tag disconnect and plug the hydraulic hoses from the platform rotate manifold A WARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 3 Support the platform mounting weldment Do not apply any lifting pressure 4 Remove the six mounting bolts from the platform mounting weldment Remove the center bolt and slide the platform mounting weldment off of the platform rotator 7 Support the jib boom jib boom cylinder and leveling links with an overhead crane 8 Use a soft metal drift to drive both pins out then remove the platform rotator from the machine A WARNING Crushing hazard The platform rotator could fall when removed from the machine if not properly supported Note When installing the platform rotator be sure to torque the fasteners to specification Refer to Specifications Machine Torque Specifications How to Bleed the Platform Rotator Note This procedure will require two people 1 Move the function enable toggle switch to either side and activate the platform rotate toggle switch to the right and then to the left through two platform rotation cycles Then hold the switch to the r
76. contact the Genie Product Support Er ss EH LN Li Li 1 1 FEE 2 1 boom function speed controller 2 drive and brake printed circuit board 3 drive joystick Platform Controls Boom Function Speed Controller Adjustments A WARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Note Do not adjust the boom function speed controller unless the static battery supply voltage is above 24V DC 1 Turn the key switch to platform controls and pull out the red Emergency Stop button to the on position at both the ground and platform controls 2 Open the platform control box lid and locate the boom function speed controller black red wire 1 2 diode 3 white red wire 4 boom function speed controller 5 ramp rate trimpot 6 threshold trimpot 7 max out trimpot Genie BRAND Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N 47 Part No 139378 mmc n
77. function enable toggle switch to either side and move and hold the primary boom extend retract toggle switch in the extend direction with the primary boom fully extended Observe the pressure reading on the pressure gauge Refer to Specifications Manifold Component Specifications Turn the machine off Hold the primary boom extend relief valve with a wrench and remove the cap item G Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Then install the relief valve cap A WARNING Tip over hazard Do not adjust the relief valve higher than specified 6 Repeatsteps 2 and 3 to confirm the relief valve pressure setting 6 Repeatsteps 2 and 3 to confirm the relief 7 Remove the pressure gauge 7 Remove the pressure gauge L 0 0 0 Part No 139378 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N 83 September 2015 _ _________________________ ___ ___ _ Manifolds How to Adjust the Turntable Rotate Relief Valve Note Perform this procedure with the boom in the stowed position 1 Connect a 0 to 3000 psi 0 to 200 bar pressure gauge to the test port on the function manifold 2 Turnthe key switch to ground control and pull out the red Emergency Stop button to the on position 3 Move and hold the function enable toggle switch to either side and move and hold the turntable rotate toggle switch in the r
78. gpm 6 8 L min after serial number 10807 24 Flow regulator valve 0 8 gpm 3 L min X Jib boom platform rotate 20 25 ft lbs 27 34 Nm circuit 25 Solenoid valve 3 position 4 way Y Turntable rotate left right 20 25 ft lbs 27 34 Nm Genie 80 Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N Part 139378 Service Manual Manifolds ken 9 509 TCO 052 QN 81 September 2015 7 WS 27 gama 92777 28 EC B 2 9 BRAND Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N Part No 139378 Service Manual September 2015 Manifolds 7 2 Valve Adjustments Function Manifold How to Adjust the System Relief Valve Note Perform this procedure with the boom in the stowed position 1 Connect a 0 to 5000 psi 0 to 350 bar pressure gauge to the test port on the function manifold 2 Turnthe key switch to ground control and pull out the red Emergency Stop button to the on position 3 Move and hold the function enable toggle switch to either side and move and hold the primary boom extend retract toggle switch in the retract direction with the primary boom fully retracted Observe the pressure reading on the pressure gauge Refer to Specifications Manifold Component Specifications 4 Turnthe machine off Hold the system relief valve with a wrench and remove
79. illustration indicate a reversed connection as specified in step 6 3 Seta multimeter to read DC current Note The multimeter when set to read DC current should be capable of reading up to 800 mA 4 Connect the negative lead to the other terminal on the coil 5 Momentarily connect the positive lead from the multimeter to the positive terminal on the 9V DC battery Note and record the current reading Genie 88 Z 30 20N Z 30 20N RJ 2 34 22 2 34 22 Part No 139378 September 2015 Service Manual Manifolds 6 Atthe battery or coil terminals reverse the connections Note and record the current reading Result Both current readings are greater than 0 mA and are different by a minimum of 2096 The coil is good Result If one or both of the current readings are 0 mA or if the two current readings do not differ by a minimum of 2096 the coil and or its internal diode are faulty and the coil should be replaced Genie BRAND Part No 139378 Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N 89 September 2015 Turntable Rotation Components 8 1 Turntable Rotation Hydraulic Motor The turntable rotation hydraulic motor is the only serviceable component of the turntable rotation assembly The worm gear must not be removed from the housing In order to remove the housing the turntable has to be removed How to Remove the Turntable Rotation Motor
80. numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 September 2015 C82JSL WH RD C30FWD WH P24BAT WH GC29JSH 5 BRN 7 BATGND BRN V BATGND BEN CIaDEL BURD 048 CISDELBURD DRIVE ENABLE LED 5 8 OSP 12 BLWH 12 CHUDEBLWH BK 5 SE 90 5 C91 DRIVE ENABLE 2 LIMIT SWITCH CAP 4 CI amp DE OR FD C4B 4 CI8DE OR RD OR RD we 8 4 TRAVEL ALARM nc 2 E RABGHICHD WH ft BRAKE RELEASE NO 5 EE Is g BRAKE RELEASE NC By a L 42 es BRAKE RELEASE d PRESSURE SWITCH wi 10 BL CIB 10 BL ni 4 STEER LEFT C878CC BLEK 1 11 BL K n 4 STEER RIGHT EN all P z 8 1 c Q m 5 5 3 5 4 1 E w E 8 lt ig 5 WH BK gt 4 HOUR METER C27AUXRD CIB WH AUX E F 253 22222 m Ese E 5 EDH m 3 8 5 3 2 B
81. of the hub Remove the inner bearing Note When removing a bearing always use a new inner bearing seal Steer Axle Components How to Install the Hub and Bearings Note When replacing a wheel bearing both the inner and outer bearings including the pressed in races must be replaced 1 Besure that both bearings are packed with clean fresh grease 2 Place the large inner bearing into the rear of the hub 3 Install a new bearing grease seal into the hub by pressing it evenly into the hub until it is flush Note Always replace the bearing grease seal when removing the hub 4 Slide the hub onto the yoke spindle Component damage hazard Do not apply excessive force or damage to the lip of the seal may occur Fill the hub cavity with clean fresh grease Place the outer bearing into the hub Install the washer and castle nut Tighten the castle nut to 158 ft lbs 214 Nm to seat the bearings N WO Note Rotate the hub by hand while torquing the castle nut to make sure the bearings seat properly Genie BRAND Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N 91 Part No 139378 Service Manual September 2015 Steer Axle Components 9 Loosen the castle nut one full turn and then torque to 35 ft lbs 47 Nm 10 Install a new cotter pin Bend the cotter pin to lock it in place Note Always use a new cotter pin when installing a castle nut 11 Install the dust cap t
82. on the turntable bearing bolts is essential to safe machine operation Improper bolt torque could result in an unsafe operating condition and component damage 1 Raise the secondary boom and place a safety chock on the lift cylinder rods Carefully lower the boom onto the lift cylinder safety chock A WARNING Crushing hazard Keep hands away from the cylinder and all moving parts when lowering the boom Note The lift cylinder safety chock is available through Genie After Market Support 2 Confirm that each turntable mounting bolt is torqued in sequence to specification Refer to Specifications Machine Torque Specifications So 8 Bolt torque sequence Genie BRAND Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N 37 Part No 139378 Checklist D Procedures Raise the secondary boom and remove the safety chocks Lower the boom to the stowed position Open the latch on the battery packs and swing them out to expose the turntable bearing bolt access hole Torque the lower bearing mounting bolts under the drive chassis in sequence to specification Refer to Specifications Machine Torque Specifications 1 4 7 60 3 2 5 8 Bolt torque sequence Service Manual September 2015 Checklist D Procedures D 4 Replace the Drive Hub Oil Genie specifications require that this procedure be performed every 1000 hours or annually whichever come
83. tank on the machine Install the hydraulic tank mounting fasteners and torque them to 8 ft lbs 10 8 Nm Component damage hazard The hydraulic tank is plastic and may become damaged if the tank mounting fasteners are over tightened Install the hydraulic hoses Fill the tank with hydraulic oil until the fluid is within the full and add marks on the hydraulic tank Do not overfill Refer to Specifications Machine Specifications Clean up any oil that may have spilled Properly discard of used oil Open the hydraulic tank shutoff valve Component damage hazard Be sure to open the hydraulic tank shutoff valve after installing the hydraulic tank Part No 139378 September 2015 2 Grease the Steer Axle Wheel Bearings 2WD Models Genie specifications require that this procedure be performed every 2000 hours or every two years whichever comes first Perform this procedure more often if dusty conditions exist Maintaining the steer axle wheel bearings is essential for safe machine operation and service life Operating the machine with loose or worn wheel bearings may cause an unsafe operating condition and continued use may result in component damage Extremely wet or dirty conditions or regular steam cleaning and pressure washing of the machine may require that this procedure be performed more often 1 Loosen the wheel lug nuts Do not remove them 2 Block the non steer whe
84. terminal then connect the negative lead from the ohmmeter to the internal ring of the valve Coil Result The resistance should be within specification plus or minus 3096 Result If the resistance is not within specification plus or minus 3096 replace the Coil 0 0 0 0 Part No 139378 Z 30 20N Z 30 20N RJ Z 34 22 2 34 22 87 Service Manual September 2015 Manifolds How to Test a Coil Diode Properly functioning coil diodes protect the electrical circuit by suppressing voltage spikes Voltage spikes naturally occur within a function circuit following the interruption of electrical current to a coil Faulty diodes can fail to protect the electrical system resulting in a tripped circuit breaker or component damage A WARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Test the coil for resistance See How to Testa Coil 2 Connect a 100 resistor to the negative terminal of a known good 9V DC battery Connect the other end of the resistor to a terminal on the coil Resistor 100 Genie part number 27287 Note The battery should read 9V DC or more when measured across the terminals COIL nO lil H 100 9 1 multimeter 2 9V DC battery 3 100 resistor 4 coil Note Dotted lines in
85. the cap item R 5 Adgjustthe internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the relief valve cap A WARNING Tip over hazard Do not adjust the relief valve higher than specified 6 Repeatsteps 2 and 3 to confirm the relief valve pressure setting 7 Remove the pressure gauge How to Adjust the Primary Boom Down Relief Valve Note Perform this procedure with the boom in the stowed position 1 Connect a 0 to 3000 psi 0 to 200 bar pressure gauge to the test port on the function manifold 2 Turnthe key switch to ground control and pull out the red Emergency Stop button to the on position 3 Move and hold the function enable toggle switch to either side and move and hold the primary boom up down toggle switch in the down direction with the primary boom fully lowered Observe the pressure reading on the pressure gauge Refer to Specifications Manifold Component Specifications 4 Turnthe machine off Hold the primary down relief valve with a wrench and remove the cap item F 5 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Then install the relief valve cap A WARNING Tip over hazard Do not adjust the relief valve higher than specified Repeat steps 2 and 3 to confirm the relief valve pressure setting 7 Remove the pressure gauge Genie 82 Z 3
86. the oil filter housing cap located on top of the reservoir 3 Remove the cap from the housing 4 Liftthe handle on the filter element and rotate the element counterclockwise to release the element from the housing 5 Remove the filter element from the filter housing Genie 38 Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N Part No 139378 September 2015 Service Manual Checklist D Procedures 6 Install the new oil filter element into the filter D 6 housing Inspect for Turntable Bearing 7 Pushthe filter element down to be sure the Wear o ring on the element is fully seated into the housing 8 Rotate the filter element clockwise to lock it in place Genie specifications require that this procedure be performed every 1000 hours or annually 9 Install the filter housing cap whichever comes first 10 Clean up any oil that may have spilled during the replacement procedure Periodic inspection of turntable bearing wear is essential to safe machine operation good machine 11 Use a permanent ink marker to write the date performance and service life Continued use of a and number of hours from the hour meter on worn turntable bearing could create an unsafe the oil filter housing operating condition resulting in death or serious inj t 5 12 Turn key switch to ground controls and pull out the red Emergency Stop button to the Note Perform this procedure with the machine on position
87. 0 20N Z 30 20N RJ 2 34 22 Z 34 22N Part No 139378 September 2015 a How to Adjust the Secondary Boom Down Relief Valve Note Perform this procedure with the boom in the stowed position 1 Connect a 0 to 3000 psi 0 to 200 bar pressure gauge to the test port on the function manifold Turn the key switch to ground control and pull out the red Emergency Stop button to the on position Move and hold the function enable toggle switch to either side and move and hold the secondary boom up down toggle switch in the down direction with the secondary boom fully lowered Observe the pressure reading on the pressure gauge Refer to Specifications Manifold Component Specifications Turn the machine off Hold the secondary boom down relief valve with a wrench and remove the cap item E Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Then install the relief valve cap A WARNING Tip over hazard Do not adjust the relief valve higher than specified Service Manual Manifolds How to Adjust the Primary Boom Extend Relief Valve Note Perform this procedure with the boom in the stowed position 1 Connect a 0 to 3000 psi 0 to 200 bar pressure gauge to the test port on the function manifold Turn the key switch to ground control and pull out the red Emergency Stop button to the on position Move and hold the
88. 0 20N RJ 2 34 22 Z 34 22N 69 Part No 139378 Service Manual September 2015 Secondary Boom Components 14 15 16 17 18 A WARNING 19 20 21 70 Remove the primary boom extend drive speed limit switch 151 mounted on the side of the primary boom at the pivot end Do not disconnect the wiring Attach a lifting strap from an overhead crane to the pivot end of the primary boom Carefully lift the secondary and primary boom assembly with the overhead crane until the master cylinder and primary boom lift cylinder hydraulic hoses are accessible Remove the cable covers from the top of the upper secondary boom Tag disconnect and plug the primary boom lift cylinder and master cylinder hydraulic hoses Cap the fittings on the cylinders Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Lower the secondary boom to the fully stowed position Pull all the cables and hoses through the upper pivot Component damage hazard Hoses can be damaged if they are kinked or pinched Position a lifting strap from the overhead crane approximately 2 feet 60 cm from the platform end of the primary boom Measure from the platform end of the primary boom tube 22 23 24 25 A WARNING Remove the pin retaining fasteners from the upper piv
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90. 1 RELAY C3P 8 COBATRDWH _ 38 3 zu un 12 MI FLASHING BEACON men Jer 4100 OPTION d E 5 25 i RD eje Lec sy SENSOR _ 2 HI g G7P 2 WH C7B 2 5 co GROUND BAS i 8 Bs l BOX D pm 1 g BKRD 9 1 COHRN 5 me B d LIFT PUMP 5 5 C48 1 R27AUX 5 i 7 CR 20 RELAY LONE 8 5 8 1 PRIMARY LIFT PUMP 5 9 24 2 0461 C19LPE PINAY Lr P22BAT 7 1 5 E 4 PR2 PRIMARY Leg ERES LIFT PUMP COIL a uM a E E 1 T GR4 RELAY Ei 2 BRN E ona i 5 BK RD 4 gt 3 2 V I t iis LS18 OVERLOAD LIMIT SWITCH i MS LSI EXT RET LIMIT SWITCH BK C101 BK pe Fir HD E BK as 54 182 PRIMARY LIMIT SWITCH T 2 E i EE PE 3 L84 SECONDARY LIMIT SWITCH 3 3 2 GROUND CHASSIS Yay spar J p H Ses CRS RELAY Em BRAKE RELEASE CET ow 1 die RD BK oe E PRI
91. 14 Orifice 0 045 inch 1 14 mm N Brake circuit 78 Genie Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N Part No 139378 Service Manual Manifolds ken 509 TCO 052 QN 79 September 2015 7 WS 27 gama 92777 28 EC B 2 9 BRAND Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N Part No 139378 Service Manual September 2015 _______ ___________ ____ ____ ___ __ Manifolds Function Manifold Components continued Index Schematic Description item Function Torque 15 Orifice 0 045 inch 1 14 mm Brake and steer circuit 16 Solenoid valve N O poppet P Brake circuit 20 25 ft Ibs 27 34 Nm 17 Differential sensing valve Q Differential sensing circuit 30 35 ft Ibs 41 47 Nm 18 Relief valve R System relief 20 25 ft lbs 27 34 Nm 2800 psi 193 bar Z 30N and Z 30N RJ 3200 psi 221 bar Z 34N and Z 34DC 19 Orifice 0 035 inch 0 89 mm S Tank return circuit 20 Diagnostic fitting T Testing 21 Solenoid valve 3 position 4 way U Secondary boom up down 20 25 ft Ibs 27 34 Nm 22 Solenoid valve 3 position 4 way V Primary boom up down 20 25 ft Ibs 27 34 Nm 23 Flow regulator valve 1 5 5 7 L min W Turntable rotate circuit 20 25 ft lbs 27 34 Nm before serial number 10808 Flow regulator valve 1 8
92. 2N Part No 139378 September 2015 Service Manual 7 4 Valve Coils How to Test a Coil A properly functioning coil provides an electromotive force which operates the solenoid valve Critical to normal operation is continuity within the coil that provides this force field A WARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or Manifolds Valve Coil Resistance Specification Note The following coil resistance specifications are at an ambient temperature of 68 F 20 C As valve coil resistance is sensitive to changes in air temperature the coil resistance will typically increase or decrease by 4 for each 18 F 10 C that your air temperature increases or decreases from 68 F 20 C Valve Coil Resistance Specification Description Specification serious injury Remove all rings Solenoid valve 3 position 4 way 20V DC 220 watchas and other jewelry schematic items A U V Y AA BB and CC 1 and disconnect the wiring from the coil to Proportional solenoid valve 24V DC 19 5 Q be tested schematic item H Solenoid valve N C t 20V DC 23 50 2 Testthe coil resistance schematic ten M ES Coils with 2 terminals Connect the leads Solenoid valve N O poppet 20V DC 2350 from the ohmmeter to the coil terminals schematic item P Coils with 1 terminal Connect the positive lead from the ohmmeter to the valve coil
93. 31 55 1 C4 amp JRL OR 2 1 X ppp d ons CAGJAL YL i 1 1 CATJRR AD A JBBOOMUP bg 70 p Ls om JIBBOOM DOWN 5 ij _ C481U GR 1 1 pog 047 4 CAND WH Gi CAMUBK 8 i RIGHT PLATFORM 2 ROTATE RIGHT Q474 OwPRLOR ELATFOHM 5 5 5 LEFT ROTATE LEFT C4r2 C18PRR BL 1 i 1 CIBPRRGREK C4B6 _ T CAPS Ci7PRLGR ces uP ae 7 4 PLATFORM LEVEL 2 E UP i t 4 PLATFORM LEVEL Su A8 DOWN DOWN n CI4PLU OR 1 1 cap CISPLDORBK C4B8 i T EXTEND a ni PRIMARY BOOM gt EXTEND t m n 4 PRIMARY BOOM RETRACT 8 RETRACT BK CSP 8 CSPBRBKWH C9b8 uP _ RD n PRIMARY 4 BOOMUP E Mr E 4 PRIMARY Bi DOWN g BOOM DOWN 5 4 1 1 1 CIPBU RD COPBDADBK 0382 n T uP QE nt SECONDARY E lt BOOM UP i 1 m BL BK ni 4 SECONDARY 3 8
94. 8 F 20 C Valve Coil Resistance Specification Description Specification Solenoid valve 3 position 4 way 20V DC 220 schematic items A J K U V Y AA AB and CC Proportional solenoid valve 24V DC 19 50 schematic Solenoid valve poppet 20V DC 23 50 schematic item M Solenoid valve N O poppet 20V DC 23 50 schematic item P Genie BRAND Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N 5 Part No 139378 September 2015 Specifications Machine Torque Specifications Platform rotator and jib boom rotator Z 30 20N RJ 1 8 center bolt GR 5 lubricated 480 ft Ibs Jib boom rotator 650 Nm 3 4 10 bolt GR 8 lubricated 280 ft lbs Platform rotator 379 Nm 3 8 16 bolts GR 8 lubricated 23 ft Ibs Platform rotator 31 Nm 1 2 13 bolts GR 5 lubricated 57 ft Ibs Jib boom rotator 77 Nm Platform rotator Z 30 20N Z 34 22 and Z 34 22N 3 4 10 bolt GR 8 lubricated 280 ft lbs 379 Nm 3 8 16 bolts GR 8 lubricated 23 ft lbs 31 Nm Turntable rotate bearing Rotate bearing mounting bolts lubricated 180 ft Ibs 244 Nm Drive hubs brakes and motors Drive hub mounting bolts lubricated 180 ft Ibs 244 Nm Brake mounting bolts lubricated 93 ft Ibs 126 Nm Drive motor mounting bolts 31 ft Ibs 42 Nm Continuous improvement of our products is a Genie policy Product specifications are s
95. Control Box Wiring Diagram ANSI CSA AS before serial numbers Z30N10 12119 Z34N10 8857 and 23410 7774 126 Electrical Schematics CE Models eee 127 Electrical Schematic CE before serial numbers Z30N10 12119 Z34N10 8857 and 23410 77774 128 Ground Control Box Terminal Strip Wiring Diagram CE before serial numbers Z30N10 12119 Z34N10 8857 and 23410 7774 132 Ground Control Box Switch Panel Wiring Diagram CE before serial numbers Z30N10 12119 Z34N10 8857 and 23410 7774 133 Platform Control Box Wiring Diagram CE before serial numbers Z30N10 12119 Z34N10 8857 and 23410 7774 136 Genie BRAND Part No 139378 Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N xiii September 2015 EEE Table of Contents Electrical Schematics ANSI and CSA Models 137 Electrical Schematic ANSI CSA from serial numbers Z30N10 12119 Z34N10 8857 and 23410 70 138 Ground Control Box Terminal Strip Wiring Diagram ANSI CSA from serial numbers Z30N10 12119 Z34N10 8857 and 23410 7774 142 Ground Control Box Switch Panel Wiring Diagram ANSI CSA from serial numbers Z30N10 12119 Z34N10 8857 and 23410 7774 143
96. D CI3DEL C4B 1 DRIVE ENABLE LIGHT BK RD CoHRN HORN 86 88 48V RELAY COIL POWER OR RD PA2BAT 80 048 2 48V POWER RD BK CASBRK CRS 85 C492 BRAKE RELEASE C2B 12 WH L29 WH 1 Bm BR 52A CR23 48V DC AD BK RD MH HORN JA DRIVE LIGHTS OPTION CONTROL RELAY SECONDARY 48V POWER CR2 PRIMARY 48 POWER AUXILIARY PUMP HORN CRS BRAKE RELEASE CR23 DRIVE LIGHTS OPTION REF 87 30 85 RELAY SOCKET SHOWN B C xu uu BR 52A 1 TS51 TS66 558 OR TS58 T 57 OR OR TS62 TS55 DESCENT ALARM WIRING O D E F TILT SENSOR BD LI _ 2 Bk _ L3 BR 52D en BK G49 7 ces d D BR C48 3 ORIRD 42A LABEL DESCRIPTION P1 EMERGENCY STOP BUTTON KS1 KEY SWITCH 7551 AUXILIARY TOGGLE SWITCH 855 FUNCTION ENABLE TOGGLE SWITCH 557 PLATFORM ROTATE TOGGLE SWITCH TS58 JIB BOOM UP DOWN TOGGLE SWITCH TS58 PLATFORM LEVEL TOGGLE SWITCH TS60 SEGONDARY BOOM UP DOWN TOGGLE SWITCH T
97. Determine the maximum platform capacity Refer to the machine serial plate Genie BRAND Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N 33 Part No 139378 Service Manual H ss Xs Un Checklist C Procedures Using a suitable lifting device place a test weight equal to that of the available capacity in one of the locations shown Refer to Illustration 1 Result The platform overload indicator lights should be off at both the ground and platform controls and the alarm should not sound September 2015 Carefully move the test weights to each remaining location on the platform Refer to Illustration 1 Result The platform overload indicator lights should be flashing at both the ground and platform controls and the alarm should sound Note There may be a 2 second delay before the overload indicator lights flash and the alarm sounds 8 the key switch to ground control 9 Using auxiliary power test all machine functions from the ground controls Result All ground control functions should not operate illustration 1 10 Using a suitable lifting device lift the additional test weight from the platform 5 Carefully move the test weights to each NEP remaining location on the platform Refer to Result The platform overload indicato
98. Fluid Properties ISO Grade 15 Viscosity index 300 Kinematic Viscosity cSt 200 F 100 C 5 5 cSt 104 F 40 C 15 0 cSt 40 F 40 C 510 Flash point 180 F 82 C Pour point 81 F 63 C Maximum continuous operating 124 F 51 C temperature Note Use of Chevron 5606A hydraulic fluid or equivalent is required when ambient temperatures are consistently below 0 F 17 C unless an oil heating system is used Continued use of Chevron 5606A hydraulic fluid or equivalent when ambient temperatures are consistently above 32 F 0 C may result in component damage Petro Canada Environ MV 46 Fluid Properties ISO Grade 46 Viscosity index 154 Kinematic Viscosity cSt 200 F 100 C 8 0 cSt 104 F 40 C 44 4 Flash point 482 F 250 C Pour point 49 F 45 C Maximum continuous operating 180 F 82 C temperature UCON Hydrolube HP 5046 Fluid Properties ISO Grade 46 Viscosity index 192 Kinematic Viscosity cSt 149 F 65 C 22 cSt 104 F 40 C 46 cSt 0 F 18 C 1300 Flash point None Pour point 81 F 63 C Maximum continuous operating 189 F 87 C temperature Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice or obligation Genie 4 Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N Part No 139378 2015 Service Man
99. Genie A TEREX BRAND Serial Number Range from 730 08 11500 Z 30 20N Em 2 30 20 RJ Z 34 22N picnic from 23407 5427 Z 34 22DC Emm Part No 139378 Rev September 2015 September 2015 Introduction Important Read understand and obey the safety rules and operating instructions in the appropriate Operator s Manual on your machine before attempting any maintenance 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 Compliance Machine Classification Group B Type 3 as defined by ISO 16368 Machine Design Life Unrestricted with proper operation inspection and scheduled maintenance 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 improvem
100. Grease the Platform Overload Mechanism if equipped 33 C 2 Test the Platform Overload System if 33 Checklist D Procedures 35 0 1 Check the Boom Wear 35 D 2 Check the Free wheel Configuration 2 36 D 3 Check the Turntable Rotation Bearing 37 0 4 Replace the Drive Hub 38 0 5 Replace the Hydraulic Tank Return Filter 38 D 6 Inspect for Turntable Bearing Wear 39 Checklist E 5 41 E 1 Test or Replace the Hydraulic Oil 41 E 2 Grease the Steer Axle Wheel Bearings 43 Section 4 Repair Procedures eerie eins 45 HU 45 Platform ERE RR RE RERO EE EX RR o 47 1 1 Controllers ati 47 Platform Components SERE DERE EE RR REEL 49 2 1 Platform Leveling Slave 49 2 2 Platform Rotator e ld eren e E
101. I _________ CTE Option CE Models 114 115 September 2015 _____________________________________________________________________________________________________________ Hydraulic Schematic September 2015 ir a Hydraulic Schematic
102. L M MANIFOLD HARNESS MH TO GROUND CONTROL BOX 181 EXTEND RETRACT LIMIT SWITCH 2 8 amp
103. LS THIS LOCATION IS USED FOR gt TS49 WORK LIGHT OPTION gt TURNTABLE TILT ALARM LED OPTION NOTES DESCRIPTION RELAY WORK LIGHTS OPTION EMERGENCY STOP BUTTON HORN BUTTON DRIVE CONTROLLER FUNCTION SPEED CONTROLLER AUXILIARY TOGGLE SWITCH JIB BOOM UP DOWN TOGGLE SWITCH PLATFORM LEVEL TOGGLE SWITCH SECONDARY BOOM UP DOWN TOGGLE SWITCH PRIMARY BOOM UP DOWN TOGGLE SWITCH TURNTABLE ROTATE TOGGLE SWITCH EXTEND RETRACT TOGGLE SWITCH JIB ROTATE TOGGLE SWITCH Z30NRJ ONLY TILT ALARM TURNTABLE TILT ALARM LED CSA OPTION BATTERY CHARGE INDIGATOR OPTION DRIVE ENABLE LED LABEL CRS BPI Tsi2 TSi5 818 Hi C132PLI 1 12 C28TTA RD BK C1P 2 P23BAT WH C7P 2 C12FTS BL WH C3P 12 C16DRE OR RD C4P 4 WH BK C3P 5 C4TRL WH C3P 4 C11SBD BLEK 11 C10SBU BL C3P 10 T510 C6MFV WH RD 6 gt 071 BP1 BK RD RD 45 86 RD BK P26BAT RD P2 ES34DCT GR BK 6 C17PRL GR C4P 5 C43JU C2P 5
104. OO 3 C47 JIB TS13 TS10 ______ P2 O NC O C2P 4 O J ooo TS8 gt 4 1 ejje elle ein 5 19 Wooo BP1 BRN BK BK RD WH RD R m 6 O eo Ts2 5 1123456 9 10 7 B DP1 ED TS6 TS4 E DO SETUP ENABLE 4 WIRE 2 CR19 i ENABLE WHEN IT IS TEMPORARILY CONNECTED TO 24VDC 3 ae 8 8 ES34DCN Part No 139378 Genie ATEREX BRAND Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N 109 September 2015 put r I M _____ _ _ GU UN __ LVI BCI Option Wiring Diagram 110 111 September 2015 Charger Interlock Option Service Manual September 2015 Charger Interlock Option A B C D E F G H K L M C49 10 LED 1 o CHARGER 3 INDICATOR C56 1 N O BATTERY BATTERY 1 E ET CHARGER CHARGER C56 1 BK NO 57 86 o CHARGER ECU C56 2 WH 2 30 85 9 C56 2 2 2 5 SUPPLY BATTERY CONTACT i NC NC OPEN 3 COIL NC CONNECT CLOSED CONNECT CONNECT OPEN 3 CONNECT NC OPEN 5 2 OR RD
105. PBR BK C3B 7 7 BKMH BK SP PRIMARY BOOM EXTEND WHIRD C3B 6 6 WHRD MH WHIRD SP FUNCTION SPEED CONTROL 5 5 WHIBK MH WHIBK SP TURNTABLE ROTATE RIGHT C5TRR WH 638 4 4 WHMH WH SP TURNTABLE ROTATE LEFT C4TRL RD BK 2 RD BK MH RD BK 8P PRIMARY BOOM DOWN C2PBD RD C3B 1 1 RD MH RD SP PRIMARY BOOM UP CiPBU D C A RD 27D TO TERMINAL GR WH 19C AND RELAY BLOCK OR RD C48 2 GR WH C49 11 1 GR2 H H RDWH CSB 3 OR RD 42D BKRDC3BO ___ RD C49 1 RD AWH 48D RD BK C49 2 1 OR RD 16A ES34DCU Genie A TEREX BRAND Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N Part No 139378 WIRES CIRCUITE FROM DESCRIPTION WH MH LS1 L82 JUNCTION BK gt cia 52 1 152 154 JUNCTION OR BK 028 3 T8 66 BP JIB ROTATE RIGHT Z30NRJ ONLY oR C282 TS 66 SP JIB ROTATE LEFT 230NRJ ONLY GR BK C2B 5 TS 58 SP JIB DOWN ar C2B 5 TS 56 SP UP oR 49 9 CH OFF LIMIT SPEED WHRD CIJEL CBS 040 6 CH JOYSTICK POT LOW WH BK C8S1REV CiB 5 049 5 CH REVERSE WH C30FWD 040 4 CH FORWARD RDAWH C29J8H C1B 3 049 3 CH 2 WIRE POT RD BK 28 TLT C 2 TILT ALARM amp TS 57 SP PLATFORM ROTATE RIGHT GR CI7PRL CABS TS 57 SP PLATFORM ROTATE LEFT BL R
106. Pack both bearings with clean fresh grease Genie BRAND Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N 43 Part No 139378 September 2015 ___ _____ ___ ___________________________ ___ _ ______ __ Checklist E Procedures 15 Place the large inner bearing into the rear of the hub 16 Install a new bearing grease seal into the hub by pressing it evenly into the hub until it is flush 17 Slide the hub onto the yoke spindle Component damage hazard Do not apply excessive force or damage to the lip of the seal may occur 18 Place the outer bearing into the hub 19 Install the washer and castle nut 20 Tighten the slotted nut to 35 ft lbs 47 Nm to seat the bearings 21 Loosen the castle nut and re tighten to 8 ft Ibs 11 Nm 22 Install a new cotter pin Bend the cotter pin to lock it in Note Always use a new cotter pin when installing a castle nut 23 Install the dust cap then the tire and wheel assembly Torque the wheel lug nuts to specification Refer to Specifications Machine Specifications Gaii 1 1 1 44 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N Part No 139378 September 2015 Service Manual Observe and Obey Repair procedures shall be completed by a person trained and qualified on the repair of this machine V Immediately tag and remove from service a damaged or malfunctioning machine V
107. Platform Control Box Wiring Diagram ANSI CSA from serial numbers Z30N10 12119 Z34N10 8857 Z3410 7774 146 Electrical Schematics AS CE Models eene 147 Electrical Schematic AS CE from serial numbers Z30N10 12119 Z34N10 8857 and 23410 77 148 Ground Control Box Terminal Strip Wiring Diagram AS CE from serial numbers Z30N10 12119 Z34N10 8857 23410 7774 152 Ground Control Box Switch Panel Wiring Diagram AS CE from serial numbers Z30N10 12119 Z34N10 8857 and 23410 7774 153 Platform Control Box Wiring Diagram AS CE from serial numbers Z30N10 12119 Z34N10 8857 Z3410 7774 156 Genie xiv Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N Part No 139378 2015 Service Manual ecc Specifications Machine Specifications Wheel lugs Front 8 5 8 18 Tires and wheels Z 30 20N Z 30 20N RJ and Z 34 22N Rear 9 Q 5 8 18 Tire size solid rubber 22x7x17 5in 199 nut torque dry E a 56 x 18 44 7600 Ibs Lug nut torque lubricated ae 3447 kg m Overall tire diameter 22in Fuel capacities 56cm Hydraulic tank 4 gallons Wheel diameter 17 5 in 15 1 liters 44 cm Hydraulic system including tank 6 gallons Wheel width 7 in 22 7 liters 18 c
108. RM LEVEL UP C14PLU ps CIRR mm ROWE DEE BLANH C3B 12 FOOTSWITCH Ci2FTS 12 BURD 084 DRIVE ENABLE LIGHT BL BK 11 11 BL BK SP SECONDARY BOOM DOWN C11SBD BGA C aaa Ep 19 ECON HORN 58820 5 BL MH ELER SECONDARY BOOM UP C1088U ROWH cabs CA1 88 CR2 86 48V RELAY COIL POWER BAYH Caes BKWHMH BKWHSP PRIMARY BOOM RETRACT CAPER BLWH C132PLI 1 12 6823 PLATFORM OVERLOAD INPUT BK C97 PRIMARY BOOM EXTEND C7PBE GREK H6 1454 PLATFORM OVERLOAD ALARM WH RD C3B 6 6 WH RD MH WHIRD SP FUNCTION SPEED CONTROL C6MFV ORB pear mem AN POWER WHIBK CaB s 5 WH BK MH WHIBK SP TURNTABLE ROTATE RIGHT C5TRR pue K m mum Snake RELEASE 4 5498 mE WH MH WHSP TURNTABLE ROTATE LEFT _G4TAL RD ena CR10A 88 86 PLATFORM LEVEL CUT OUT RD BK C3B 2 2 RO BK MH RD BK SP PRIMARY BOOM DOWN C2PBD RD 1 RD MH RD SP PRIMARY BOOM UP D C2B 12 RD 27D L29 TO TERMINAL BASE MEL GR WH 19C WH ue AND RELAY BLOCK OR RD C48 2 GR AWH C49 11 BK 22A GND BR H H BR 52A ABS CR23 RD WH C3B 3 cn 48VDC Fig RD BK RD MH HORN DRIVE LIGHTS OPTION OR RD 42D BK RD C3B 9 RD C49 1 CONTROL RELAY RDWH 48D CR1 SECONDARY 48V POWER CR2 PRIMARY 48V POWER CR5 CR3 AUXILIARY PUMP FS HORN RD BK C49 2
109. RS Wi 8 gt RD 8 8 AUXILIARY CONTROL 85 8 8 89 E BR WH E ph C497 GAH GRWH LF 8 2115 Ci9LPE GR WH x g 5 C3P 6 COMFY WH RD C3B 6 WHRD PROPORTIONAL 421 9 6 CoNTROLVALVE g 5 JEER s 8 E 5 WH E 5998 1 1 tert 55 noes 5 55 1 aE te F Eal E 99 2 C47JRR 28 3 OR BK 55 gt 6 IL 2 2 CABJRL OR C252 i JIBBOOM up ROTATE LEFT JIBBOOM 1 ROTATE RIGHT DOWN LN aa 5 E Be jw caps cuan 628 5 GR C2P 6 44 0 GRIBK C2B 5 GR BK DOWN d 1111 JIB BOOM DOWN CASU EK 11 i RIGHT JIBBOOM i QE CITPRLOR 3 SE ABLET PLATFORM gg ROTATELEFT C47 2 BL 4 PLATFORM P ROTATE RIGHT 6 GR BK 4 CIZPRLOR CABS 2 is UP on a PLATFORM LEVEL b UP 5
110. RY 04 Poona FDOIBH E mE E WHIRD C496 JOYSTICK POT LOW WH BK Ca2 4 22 24V TO PLATFORM P22BAT Viu ouis REVERSE TB36 TB37 GRAWH CRS 19 GRWHMH LIFT PUMP C19LPE Wd 8 chi n FORWARD TC OR WH 7 19 GRMWH SP LIFT PUMP C19LPE EUM PET eins EUN MEET ORRD OR RD C4B 4 16 OR RD CRS DRIVE ENABLE AAR mm ida ORBK 4 15 OR BK MH OR BK SP PLATFORM LEVEL DOWN GISPLD nk PEE PEE MAHT ORO4B2 14 8 PLATFORM LEVEL SP PLATFORM ROTATE LEFT 12 ANE CH BK BLAH 12 B FOOTSWITEH curre BLAD C1SDEL ced DRIVE ENABLE LIGHT BL BK 11 1 BUBK MH BL BK GP SECONDARY BOOM DOWN m eS mum EE 19 mE SEGONDARY BOOM UP GIOSEU RDAWH CoB 3 486 CR2 486 4BV RELAY COIL POWER BKAWH 8 8 BKAWH MH BKAWH SP PRIMARY BOOM RETRACT C amp PBR RD PEAT Cm eo ES Us POWER BK C38 7 7 BkMH PRIMARY EXTEND 7 RD SK CARBRK GRE WE 042 BRAKE RELEASE WH RD 6 6 WHRD MH WH RD SP FUNCTION SPEED CONTROL 6 WH BK CSB 5 WHBK MH WHIBK SP TURNTABLE ROTATE RIGHT C5TRR WH 38 4 4 WHMH 8 TURNTABLE ROTATE LEFT C4TRL RD BK C3B 2 2 RD BK MH RD BK SP PRIMARY BOOM DOWN C2PBD RD C354 1 RD MH RD SP PRIMARY BOOM UP 1
111. Repair any machine damage or malfunction before operating the machine Before Repairs Start MI 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 parts available and ready for use Read each procedure completely and adhere to the instructions Attempting shortcuts may produce hazardous conditions Part No 139378 Use only Genie approved replacement parts Repair Procedures Machine Configuration Unless otherwise specified perform each repair procedure with the machine in the following configuration e Machine parked on a firm level surface Key switch in the off position with the key removed e The red Emergency Stop button in the off position at both ground and platform controls e Wheels chocked All external AC power supply disconnected from the machine the stowed position e Turntable secured with the turntable rotation lock Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N 45 September 2015 Repair Procedures About This Section Most of the procedures in this section should only be performed by trained service professional in a suitably equipped workshop Select the appropriate repair procedure after troubleshooting the problem Perform disassembly procedures to the point where repairs can be completed
112. S61 PRIMARY BOOM UP DOWN TOGGLE SWITCH T862 TURNTABLE ROTATE TOGGLE SWITCH TS63 PRIMARY BOOM EXTEND RETRACT TOGGLE SWITCH 966 JIB ROTATE TOGGLE SWITCH Z30NRJ ONLY CIRCUIT BREAKER CONTROLS 10A CIRCUIT BREAKER CONTROLS RETURN 10A HM HOURMETER CHASSIS HARNESS MH MANIFOLD HARNESS SP SWITCH PANEL CONTROL RELAY H3 TRAVEL ALARM H4 DESCENT ALARM OPTION L3 CONTROLLER STATUS LED September 2015 Service Manual Ground Control Box Switch Panel Wiring Diagram ANSI CSA from serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 TO TERMINAL BASE AND CONNECTORS J K M RD WH 48A BR 52A SWITCH PANEL O O GN BK WHI BK 18C 48C C32 12 ONCO NCO HM RD C48 1 CB2 RD 134A BK 22A RD C23 6 I _ JIB ROTATE 230 MODELS BL WH C1 12 220 BK C7 1 Qd 9 EcO QH BV MENS BR HMC RD 27A OR BK 15A BK 7A BKANH 8A WH RD 6A OR BK C2 3 OR G2 2 20 Ou 5 14 GN BK 18A GN WH 19A E e e 1357 GN BK 44A GN 43A a cA Qog 5 5 RD BK 2A RD 1A
113. September 2015 Service Manual 51 Use a slide hammer to remove the barrel end pivot pins access the pins from the access holes in the bulkheads one on each side Remove the secondary boom lift cylinder from the machine A WARNING unbalanced and fall when removed from the machine if not properly attached to the overhead crane 52 Attach a lifting strap from an overhead crane to the mid pivot for support 53 Remove the pin retaining fasteners from the mid pivot to the lower secondary compression arm pivot pins Use a slide hammer and remove the pins Lower the compression arms down 54 Remove the pin retaining fasteners from the mid pivot to the lower secondary boom pivot pin Use a soft metal drift to remove the pins 55 Remove the mid pivot from the machine A WARNING could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane 56 Remove the secondary boom drive speed limit Switch 154 mounted to the turntable riser on the ground controls side Do not disconnect the wiring Genie 1 1 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N 73 Part No 139378 Crushing hazard The secondary boom lift cylinder could become Crushing hazard The mid pivot 57 59 AWARNING 60 Secondary Boom Components Attach a lifting strap from an overhead crane to the ground control side lower secondary boom compression arm Remo
114. Service Manual September 2015 Checklist B Procedures B 10 Test the Drive Speed Raised or Extended Position Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Proper drive functions are essential to safe machine operation The drive function should respond quickly and smoothly to operator control Drive performance should also be free of hesitation jerking and unusual noise over the entire proportionally controlled speed range Note Select a test area that is firm level and free of obstructions 1 Create start and finish lines by marking two lines on the ground 40 feet 12 2 m apart 2 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the start and finish lines 3 Bring the machine to top drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line 4 Continue at full speed and note the time when the machine reference point crosses the finish line Refer to Specifications Performance Specifications 28 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N Lower the boom to the stowed position and extend the boom 1 foot 30 cm Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the start and finish lines Bring the machine to top drive speed before reaching the s
115. TCH 981 PRIMARY UP DOWN TOGGLE SWITCH 1562 TURNTABLE ROTATE TOGGLE SWITCH 1563 PRIMARY BOOM EXTEND RETRACT TOGGLE SWITCH TS66 JIB ROTATE TOGGLE SWITCH Z30N RJ ONLY CIRCUIT BREAKER CONTROLS 10A GIRGUIT BREAKER CONTROLS RETURN 10 HM HOURMETER CH CHASSIS HARNESS MH MANIFOLD HARNESS SP SWITCH PANEL CR CONTROL RELAY TRAVEL ALARM H4 DESCENT ALARM H6 PLATFORM OVERLOAD ALARM 13 CONTROLLER STATUS LED L45 PLATFORM OVERLOAD LED September 2015 Service Manual Ground Control Box Switch Panel Wiring Diagram AS CE from serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 G H K L M RD C321 52 22222225 1 H3 Pa BR E2A i 1 SWITCH PANEL RD 1348 9 2 BURD C2B 1 1 WHIBK 19D AASC BR C92 12 ONCO 1 i TO TERMINAL BASE NGO HM 3 RD C48 1 1 2
116. TOR RELAY PRIMARY LIFT PUMP PRZ HORN RELAY HORN L81 EXT RET LS2 PRI UP DWN 184 8 UPIDWN CHASSIS GROUND BRAKE RELEABE RELAY GR5 PR1 DRIVE CONTACTOR PRIMARY LIFT PUMP AUXILIARY LIFT PUMP 1 ALL UMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED gt SWITCH SHOWN WITH BOOM EXTENDED NOTES SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON STEER WHEEL 4 ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED gt SETUP ENABLE USE SET THE BATTERY INDICATOR PROFILES Genie Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N Part No 139378 138 Service Manual September 2015 Electrical Schematic ANSI CSA from serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 C29JSH RD WH C28JSH RD WH T N e BRN C7P 3 BATGND OTBSBATGNDBRN 4 CHGDELBURD 0484 WHE A BANS 8 4 AE 7 41 4 12 2 C3B
117. Then to re assemble perform the disassembly steps in reverse order Symbols Legend Safety alert symbol used to alert A personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death A DANGER Indicates a imminently hazardous situation which if not avoided will result in death or serious injury AWARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury Indicates a potentially hazardous A CAUTION situation which if not avoided may cause minor or moderate injury Indicates 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 46 Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N Part 139378 2015 Service Manual 1 1 Controllers The drive joystick is connected to the drive motor controller located under the drive chassis cover at the non steer end of the machine Maintaining the boom function speed controller at the proper settings is essential to safe machine operation The boom function speed controller should operate smoothly and provide proportional speed control through its entire range of motion For further information or assistance
118. WN WITH BOOM ROTATED PAST EITHER NON STEER WHEEL 4 ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED gt SETUP ENABLE USE SET THE BATTERY INDICATOR PROFILES 8 Genie Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N Part No 139378 118 Service Manual C 2J5L WH RD C81REV C3oFWD WH Electrical Schematic ANSI CSA AS before serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 September 2015 C28J8H C32J5L WHRD C30FWD WH N e N BRN BATGND CTE 8 BATGND 5 a GY C13DEL BLAD BLAD C84 BANS cea E 4 AL 8 DRIVE ENABLE 12 CIPFTSBLWH 77 09 12 C12FTS BLWH 5 PEE UMITSWITCH NA x X ORAD gt ORMD a 5 JE TRAVELALARM g p 8 2 Si F4SBRK m BRAKE RELEASE
119. a firm level surface with the boom in the stowed 13 Move and hold the function enable toggle position switch to either side and move and hold the 1 Grease the turntable bearing Refer to primary boom toggle switch in the up direction Maintenance Procedure Grease the 14 Inspect the filter housing and related Turntable Bearing and Rotate Gear Part No 139378 components to be sure that there are no leaks 2 Torque the turntable bearing bolts to specification Refer to Maintenance Procedure Check the Turntable Rotation Bearing Bolts 3 Raise the primary and secondary booms to full height using the ground controls Do not extend the primary boom Genie BRAND Z 30 20N Z 30 20N RJ e Z 34 22 Z 34 22N 39 Service Manual Checklist D Procedures Place a dial indicator between the drive chassis and the turntable at a point that is directly under or inline with the boom and n more than 1 inch 2 5 cm from the bearing Note To obtain an accurate measurement place the dial indicator no more than 1 inch 2 5 cm fro the turntable rotation bearing 0 2 0 4 1 turntable 2 dial indicator 3 drive chassis 4 turntable rotation bearing Adjust the dial indicator needle to the zero position Lower the secondary boom to the stowed position and lower the primary boom to a horizontal position Fully extend the primary boom 40 m 11 12 Ge
120. ae 50 2 3 Platform Overload 51 Jib Boom Componhents 5 erento EE ERR a pue dE te rk ERR RR E Era Eu ER 54 3 1 Platform Overload 54 3 2 Jib Boom Bell Crank models without rotating jib 55 3 3 Jib Boom Bell Crank models with rotating jib 56 3 4 Jib Boom Litt Gylinder 58 Genie X Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N Part No 139378 September 2015 Table of Contents Primary Boom 59 4 1 Cable 59 4 2 BOOM 60 4 3 Primary Boom Lift Cylinder 2 63 4 4 Primary Boom Extension Cylinder nmn 65 4 5 Platform Leveling Master Cylinder 67 Secondary Boom Components esee nennen nennen nnns 68 5 1 Secondary citet tiii lei E PE Eon baba ute 69 5 2 Secondary Boom Lift Cylinders sese 74 Hydraulic PUMP enne nnn nnn nnne nnn nnn tria tente 77 6 1 Auxiliary and Function 77
121. ag disconnect and plug the jib boom lift cylinder hydraulic hoses Cap the fittings on the jib boom lift cylinder 4 Remove the cable cover from the side of the jib boom 5 Remove the mounting fasteners from the jib boom platform rotate manifold and lay the manifold to the side Do not remove the hoses or disconnect the wiring Component damage hazard Hoses can be damaged if they are kinked or pinched Genie Models with rotating jib boom Tag disconnect and plug the hydraulic hoses from the jib boom rotator Cap the fittings on the rotator manifold AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Attach a lifting strap from an overhead crane to the jib boom Models without rotating jib boom Remove the pin retaining fastener from the jib boom pivot pin at the jib boom bellcrank Use a soft metal drift to remove the pin then remove the jib boom from the jib boom bellcrank AWARNING Crushing hazard The jib boom could fall when the pin is removed if not properly supported by the overhead crane Models with rotating jib boom Remove the pin retaining fastener from the jib boom pivot pin at the jib boom rotator Use a soft metal drift to remove the pin then remove the jib boom from the jib boom rotator AWARNING Crushing hazard The jib boom cou
122. ard Beware of hot oil Contact with hot oil may cause severe burns Genie 74 Z 30 20N Z 30 20N RJ 2 34 22 2 34 22 Part No 139378 2015 Service Manual Secondary Boom Components 9 Tag disconnect and plug the hydraulic hose 16 Attach a lifting strap from an overhead crane from the hydraulic tank return filter housing to the lug on the rod end of the secondary Cap the fitting on the filter housing boom lift cylinder A WARNING Bodily injury hazard Spraying 17 From the bottom side of the cylinder remove hydraulic oil can penetrate and the retaining fasteners from the secondary burn skin Loosen hydraulic boom lift cylinder barrel end pivot pins 2 ui 2 is 18 Remove the hose clamp under the lower oil pressure to dissipate secondary boom gradually Do not allow oil to squirt or spray 19 Use a slide hammer to remove both barrel end pivot pins access the pins from the access ACAUTION Bodily injury hazard Beware of holes in the bulkheads one on each side ides Pan 20 Remove the pin retaining fastener from the ane secondary boom lift cylinder pivot pin 10 Remove the hydraulic tank mounting 21 Use a soft metal drift to remove the secondary fasteners Remove the hydraulic tank from the boom rod end pivot pin machine d Th d rushing hazard The secondary 11 Open the ground controls side turntable cover AWARNING boom lift cylinder may fall when 12 Remove t
123. ations Hydraulic Fluid Specifications Genie specifications require hydraulic oils which are designed to give maximum protection to hydraulic systems have the ability to perform over a wide temperature range and the viscosity index should exceed 140 They should provide excellent antiwear oxidation prevention corrosion inhibition seal conditioning and foam and aeration suppression properties Cleanliness level ISO 15 13 minimum Water content 250 ppm maximum Recommended Hydraulic Fluid Hydraulic oil type Chevron Rando HD Premium Viscosity grade 32 Viscosity index 200 Optional Hydraulic Fluids Shell Tellus S2 V 32 Shell Tellus S2 V 46 Chevron 5606A Petro Canada Environ MV 46 UCON Hydrolube HP 5046 Note Genie specifications require additional equipment and special installation instructions for the approved optional fluids Consult Genie Product Support before use Mineral based Biodegradable Fire resistant Optional fluids may not have the same hydraulic lifespan and may result in component damage Note Extended machine operation can cause the hydraulic fluid temperature to increase beyond it s maximum allowable range If the hydraulic fluid temperature consistently exceeds 200 F 90 C an optional oil cooler may be required Specifications Do not top off with incompatible hydraulic fluids Hydraulic fluids may be incompatible due to the differences in base add
124. be damaged if it is twisted The primary boom cable track guides the cables and hoses running up the boom It can be repaired link by link without removing the cables and hoses that run through it Removing the entire primary boom cable track is only necessary when performing major repairs that involve removing the primary boom Note A 7 link repair section of cable track is available through the Genie Service Parts Department 1 link separation point 2 lower clip 1 Useaslotted screwdriver to pry down on the lower clip 2 Toremove a single link open the lower clip and then use a screw driver to pry the link to the side 3 Repeat steps 1 and 2 for each link Genie BRAND Part No 139378 Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N 59 September 2015 Primary Boom Components How to Shim the Primary Boom 1 Extend the boom until the wear pads are accessible 2 Loosen the wear pad mounting fasteners 3 Install the new shims under the wear pad to obtain zero clearance and zero drag 4 Tighten the mounting fasteners Extend and retract the boom through an entire cycle Check for tight spots that could cause scraping or binding Note Always maintain squareness between the outer and inner boom tubes How to Remove the Primary Boom A WARNING Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable works
125. chine Repeat this step for the hydraulic tank side upper secondary compression arm Crushing hazard The upper secondary compression arm could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane 30 Close the hydraulic tank shutoff valve Tag disconnect and plug the hydraulic hose from the hydraulic tank shutoff valve Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Open the valve on the hydraulic tank and drain the oil into a container of suitable capacity Refer to Section 2 Specifications Bodily injury hazard Beware of hot oil Contact with hot oil may cause severe burns 32 A WARNING CAUTION 33 35 36 37 38 39 Tag disconnect and plug the hydraulic hose from the hydraulic tank return filter housing Cap the fitting on the filter housing Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Bodily injury hazard Beware of hot oil Contact with hot oil may cause severe burns Remove the hydraulic tank mounting fasteners Remove the hydraulic tank from the machine Open the ground controls side turntable cover Remove the termi
126. component damage and unsafe operating conditions 1 Measure each wear pad Replace the wear pad once it reaches the minimum allowable thickness If the wear pad is still within specification shim as necessary to obtain minimum clearance with zero binding 2 Extend and retract the boom through the entire range of motion to check for tight spots that may cause binding or scraping of the boom Checklist D Procedures Note Always maintain squareness between the outer and inner boom tubes Models without rotating jib boom Primary boom wear pad specifications Minimum Top and side wear pads 5 8 inch extension end of boom 15 9 mm Bottom wear pads 5 8 inch extension end of boom 15 9 mm Bottom and side wear pads 5 8 inch pivot end of boom 15 9 mm Top wear pads 3 8 inch pivot end of boom 9 5 mm Models with rotating jib boom Primary boom wear pad specifications Minimum All wear pads 3 8 inch 9 5 mm Genie BRAND Part No 139378 2 30 20 Z 30 20N RJ e Z 34 22 Z 34 22N 35 Service Manual September 2015 Checklist D Procedures D 2 Check the Free wheel Configuration Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first Proper use of the free wheel configuration is essential to safe machine operation The free wheel configuration is used primarily for towing A machine configured to free wheel without op
127. ctrical Schematic ANSI CSA AS before serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 September 2015 Service Manual Electrical Schematic ANSI CSA AS before serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 C28JSH RD WH N Ut A 1 Ba E EF 5 E FEE 8 8 8 555 g 5 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 d 1 1 1 1 I 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Ce eee 2 1 1 1 325 8 4 BK WH amp BKWHC2B 12 WH 18 2 8 E 1 N Ig 4 88 1 7 f wh 385 7 1 1 svi PABLPS WHIRD G1P 8 RA2BATORIRD 18 8 WHIRD 1 1 1 1 I 1 1 1 1 1 1 1 1 1 1
128. cylinder the O ring if equipped on the fitting and or hose end must be replaced All connections must be 6 p i 2 ris torqued to specification during installation Refer to uc iom Sr parre FS pin ste Specifications Hydraulic Hose and Fitting Torque t metal drift to remove the barrel end pivot Specifications pin P 7 Use a soft metal drift to remove the jib boom 1 jan e a m 2 lift cylinder rod end pivot Remove the jib UNEEI M NSN boom lift cylinder from the machine lower the jib boom until the platform is resting on the blocks just enough to support the Crushing hazard The jib boom platform A WARNING lift cylinder may become Note Do not rest the entire weight of the boom on unbalanced and fall when itis removed from the machine if it is the blocks not properly supported by the 2 Tag disconnect and plug the jib boom lift overhead crane cylinder hydraulic hoses Cap the fittings on the cylinder A WARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Genie 58 Z 30 20N Z 30 20N RJ 2 34 22 2 34 22 Part No 139378 September 2015 Service Manual Primary Boom Components 4 1 How to Repair the Primary Boom Cable Track Cable Track Component damage hazard The boom cable track can
129. d the platform rotate toggle Switch to the right position until the platform is fully rotated to the right Continue holding the toggle switch until air stops coming out of the bleed screw Close the bleed screw A WARNING Crushing hazard Keep clear of the platform during rotation 7 Clean up any hydraulic oil that may have spilled 8 Rotate the platform fully in both directions and inspect the bleed screws for leaks Platform Components 2 3 Platform Overload System How to Calibrate the Platform Overload System Calibration of the platform overload system is essential to safe machine operation Continued use of an improperly calibrated platform overload system could result in the system failing to sense an overloaded platform The stability of the machine is compromised and it could tip over Note Perform this procedure with the machine on a firm level surface 1 Turn the key switch to platform control 2 Determine the maximum platform capacity Refer to the machine serial plate 3 Remove all weight tools and accessories from the platform Note Failure to remove all weight tools and accessories from the platform will result in an incorrect calibration 4 Using a suitable lifting device place a test weight equal to the maximum platform capacity at the center of the platform floor Genie BRAND Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N 51 Part No 139378 Service Manual Se
130. d to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications 1 Remove the jib boom Refer to Repair Procedure How to Remove the Jib Boom 2 Support and secure the jib boom rotator to an appropriate lifting device 3 Remove the eight mounting bolts from the jib boom rotator mount 4 Remove the center bolt Carefully remove the jib boom rotator from the machine AWARNING Crushing hazard The jib boom rotator could become unbalanced and fall when removed from the machine if not properly supported and secured to the lifting device Note When installing the jib boom rotator be sure to torque the fasteners to specification Refer to Specifications Machine Torque Specifications 5 Support and secure the jib boom bell crank to an appropriate lifting device 10 Remove the pin retaining fasteners from the slave cylinder rod end pivot pin Do not remove the pin Place a block of wood under the platform leveling slave cylinder for support Protect the cylinder rod from damage Remove the pin retaining fasteners from the jib boom bell crank at the extension boom Use a soft metal drift to remove the pin Use a soft metal drift to remove the slave cylinder rod end pivot pin Remove the jib boom bell crank from the extension boom AWARNING Crushing hazard The jib boom bellcrank may become unbalanced and fall if it is not properly supported when it is removed fro
131. death or serious injury and significant component damage Dealer service is strongly recommended Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications 1 Raise the secondary boom until both the rod end and barrel end pivot pins of the master cylinder are accessible Primary Boom Components 2 Tag disconnect and plug the master cylinder hydraulic hoses Cap the fittings on the cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 3 Attach an overhead crane or similar lifting device to the master cylinder 4 Remove the pin retaining fasteners from the master cylinder barrel end pivot pin Use a soft metal drift to remove the pin A WARNING Crushing hazard The master cylinder could become unbalanced and fall if not properly attached to the overhead crane 5 Remove the pin retaining fastener from the rodend pivot pin 6 Place arod through the rod end pivot pin and twist to remove the pin 7 Remove the master cylinder from the machine A WARNING Crushing hazard The master cylinder could become unbalanced and fall if not proper
132. djust the specific gravity reading for each cell as follows e Add 0 004 to the reading of each cell for every 10 5 5 C above 80 26 7 C e Subtract 0 004 from the reading of each cell for every 10 5 5 C below 80 F 26 7 C Result All battery cells display an adjusted specific gravity of 1 277 or higher The battery is fully charged Proceed to step 11 g Result One or more battery cells display specific gravity of 1 217 or below Proceed to step 8 8 Perform an equalizing charge OR fully charge the battery s and allow the battery s to rest at least 6 hours 9 Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer Note the results Genie BRAND Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N 21 Part No 139378 September 2015 Checklist B Procedures 10 Check the ambient air temperature and adjust the specific gravity reading for each cell as follows Add 0 004 to the reading of each cell for every 10 5 5 C above 80 F 26 7 C e Subtract 0 004 from the reading of each cell for every 10 5 5 C below 80 26 7 C Result All battery cells display a specific gravity of 1 277 or greater The battery is fully charged Proceed to step 11 Result One or more battery cells display specific gravity from 1 218 to 1 269 The battery is still usable but at a lo
133. draulic oil the oil may be tested by an oil distributor for specific levels of contamination to verify that changing the oil is necessary If the hydraulic oil is not replaced at the two year inspection test the oil quarterly Replace the oil when it fails the test Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications Note Perform this procedure with the boom in the stowed position Checklist E Procedures 1 Close the two hydraulic tank shut off valves at the hydraulic tank open closed Component damage hazard The engine must not be started with the hydraulic tank shut off valves in the closed position or component damage will occur If the tank valves are closed remove the key from the key switch and tag the machine to inform personnel of the condition 2 Place a suitable container under the hydraulic tank Refer to Section 2 Specifications 3 Tag disconnect and plug the hydraulic hose from the hydraulic tank shutoff valve AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Genie BRAND Z 30 20N Z 30 20N RJ 2 34 22
134. e replace the motor controller Forward Bias Test Desired result Positive Lead Negative Lead M 0 4 to 0 45 B M 0 4 to 0 45 F1 0 45 to 0 5 F2 0 45 to 0 5 B F1 0 45 to 0 5 B F2 0 45 to 0 5 Reverse Bias disconnect the battery packs from the Test Desired result machine Positive Lead Negative Lead 2 Tagand disconnect all power cables from the B M Rises to 01 V motor controller M B Rises to 01 V AWARNING Electrocution burn hazard B F1 Rises to OL V Contact with electrically charged 22 Rises to 01 V circuits could result in death F1 B Rises to OL V serious injury Remove all rings watches and other jewelry F2 B Rises to OL 3 Press the release tab on the motor controller harness connector and remove the motor controller harness connector from the motor controller Genie Part No 139378 Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N 93 September 2015 Fault Codes Observe and Obey 94 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 Unless otherwise specified perform each procedure with the machine in the following configuration e Machine parked on a firm lev
135. e hex nut until the mark on the hex nut is aligned with the second mark on the body hex fitting 5 Operate all machine functions and inspect the hose fittings and related components to confirm there are no leaks Genie BRAND Part No 139378 Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N 9 September 2015 Specifications SAE FASTENER TORQUE CHART This chart is to be used as a guide only unless noted elsewhere in this manual A574 High Strength THREAD Grade 5 Grade 8 65 indbs Nm inibs Nm indbs Nm in ibs Nm Nm 44 ___20 80 9 10 13 110 124 140 158 130 147 28 90 101 120 135 120 135 160 18 140 158 LUBED LUBED fttbs Nm ftibs Nm Nm ft lbs Nm Nm _ 546 ___18 13 176 17 23 18 24 25 339 21 284 24 14 19 19 257 20 271 27 366 24 325 16 23 312 31 42 33 447 44 596 38 515 _ 24 __ _26 352 35 474 37 501 49 664 43 J 583 me __14 37 50 1 49 664 50 678 70 947 61 827 20 _ _41 e0 813 80 1084 68 921 101 6 80 1084 110 149 93 126 90 120 130 77 3 86 7 108 4 122 75 12 115 149 120 162 150 203 130 176 162 130 176 170 230 140 189 160 217 210 284
136. ecifications Hydraulic Hose and Fitting Torque Specifications 1 Remove the counterweight cover 2 Place a suitable lifting device under the platform for support 3 Disconnect the battery packs from the machine 4 Remove the cable cover from the side of the jib boom platform control box 6 Locate the cables from the primary boom cable track to the platform control box Number each cable and its entry location at the platform control box 7 Open the platform control box Tag and disconnect each wire from the cables in the platform control box A WARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 9 Pullthe cables out of the platform control box 10 Pull all of the electrical cables out of the plastic cable track Do not pull out the hydraulic hoses 11 Remove the hose clamps from the bottom side of the primary boom 12 Tag disconnect and plug the hydraulic hoses from the P and T ports at the jib boom rotate manifold Cap the fittings on the manifold A WARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 13 Remove the hose clamp from the side of the primary boom at the pivot end Genie BRAND Z 30 20N Z 3
137. ee it coming out of the side of the gear housing 5 Grease each tooth on the outside of the turntable rotation bearing Grease Specification Chevron Ultra duty grease EP NLGI 2 lithium based or equivalent Genie BRAND Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N 19 Part No 139378 Service Manual September 2015 Checklist A Procedures A 6 4 Replace the Drive Hub Oil Drive hub specifications require that this one time procedure be performed after the first 150 hours of usage After this interval refer to the maintenance checklist for continued scheduled maintenance Replacing the drive hub oil is essential for good machine performance and service life Failure to replace the drive hub may cause the machine to perform poorly and continued use may cause component damage 1 Select the drive hub to be serviced Drive the machine until one of the two plugs is at the lowest point 2 Remove the plugs and drain the oil into suitable container 3 Drive the machine until one of the two plugs is at the highest point 1 drive hub plugs Genie Fill the hub until the oil level is even with the bottom of the lowest plug hole Refer to Specifications Machine Specifications Install the plugs into the drive hub Repeat this procedure for each drive hub 20 Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N Part 139378 September 2015 Service Manual B 1 Inspec
138. el e Function manifold wiring Genie 22 Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N Part No 139378 September 2015 Service Manual 3 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 4 Raise the secondary boom until the mid pivot is approximately 10 feet 3 m off the ground 5 Inspect the turntable center area for burnt chafed and pinched cables 6 Lower the boom to the stowed position and turn the machine off 7 Inspect the following areas for burnt chafed corroded pinched and loose wires e Cable track on the primary boom e Primary boom to platform cable harness e Inside of the platform control box 8 Inspectfor a liberal coating of dielectric grease at the following location e All wire harness connectors to the platform control box e All wire harness connectors located under the ground control side turntable cover e Harness connector to the drive motor controller located in the non steer end of the drive chassis Checklist B Procedures B 3 Inspect the Tires Wheels and Lug Nut Torque Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining the tires and wheels including proper wheel fastener torque is essential to safe operation and good performance Tire and or wheel failure could result in a machine tip over Comp
139. el surface Key switch in the off position with the key removed e The red Emergency Stop button in the off position at both ground and platform controls Wheels chocked All external AC power supply disconnected from the machine Boom in the stowed position Turntable secured with the turntable rotation lock Welder disconnected from the machine if equipped with the weld cable to platform option 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 Read each appropriate fault code thoroughly Attempting short cuts may produce hazardous conditions V Be aware of the following hazards and follow generally accepted safe workshop practices A WARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Note Two persons will be required to safely perform some troubleshooting procedures h 1 1 11 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N Part No 139378 September 2015 Service Manual Fault Codes Tip over hazard When A DANGER adjusting the raised drive speed settings the maximum raised drive speed must not exceed 0 6 mph 1Km h or 40 feet 45 seconds 12 2
140. els then center a lifting jack under the steer axle 3 Raisethe machine 6 inches 15 cm and place blocks under the drive chassis for support 4 Remove the lug nuts Remove the tire and wheel assembly 5 Check for wheel bearing wear by attempting to move the wheel hub side to side then up and down Result There should be no side to side or up and down movement Skip to step 10 if there is no movement Checklist E Procedures 6 Remove the dust cap from the hub Remove the cotter pin from the castle nut 7 Tighten the castle nut to 35 ft Ibs 47 Nm to seat the bearings 8 Loosen the castle nut and re tighten to 8 ft Ibs 11 Nm 9 Check for wheel bearing wear by attempting to move the wheel hub side to side then up and down Result If there is no side to side or up and down movement continue with step 11 and grease the wheel bearings Result If there is side to side or up and down movement continue to step 11 and replace the wheel bearings with new ones Note When replacing a wheel bearing both the inner and outer bearings including the pressed in races must be replaced 10 Remove the dust cap from the hub Remove the cotter pin from the castle nut 11 Remove the castle nut 12 Pull the hub off of the spindle The washer and outer bearing should fall loose from the hub 13 Place the hub on a flat surface and gently pry the bearing seal out of the hub Remove the rear bearing 14
141. ent All communications will be carefully considered for future printings of this and all other manuals Contact Us Internet www genielift com E mail awp techpub terex com Genie i Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N Find a Manual for this Model Go to http www genielift com Use the links to locate Operator s Parts or Service Manuals Copyright 2011 by Terex Corporation 139378 Rev C September 2015 Third Edition Third Printing Genie is a registered trademark of Terex South Dakota Inc in the U S A and many other countries Z is a trademark of Terex South Dakota Inc Part No 139378 2015 Service Manual Introduction Revision History Revision Date Section Procedure Page Description B2 1 2015 Introduction Added Revision History Maint Added B 15 Test the Emergency Power C 9 2015 Added ending serial breaks Reference Examples Section Maintenance B 3 Section Repair Procedure 4 2 Electronic Version 7 Click on any content or procedure in the Table of Contents to view Section Fault Codes All charts the update Section Schematics Legends and schematics Genie BRAND Part No 139378 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N iii September 2015 Introduction Revision History Revision Date Section Procedure Page Description
142. er side and move and hold the jib vee pl and boom rotate toggle switch to the right for aes approximately 5 seconds then release it Crushing hazard Keep hands Repeat three times A WARNING 9 p and head clear of the platform A WARNING Crushing hazard Keep hands pivot weldment during rotation and head clear of the platform pivot weldment during rotation 11 Turn the key switch to the off position and clean up any hydraulic oil that may have 4 Move and hold the function enable switch to spilled either side and move and hold the jib boom rotate toggle switch to the left for approximately 5 seconds then release it Repeat three times Genie BRAND Part No 139378 Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N 57 Service Manual September 2015 Jib Boom Components 3 4 3 Remove the pin retaining fasteners from the Jib Boom Lift Cylinder jib boom lift cylinder rod end pivot pin Do not remove the pin 5 5 4 Use soft metal drift to tap the rod end pivot How to Remove the Jib Boom Lift pin half way out and lower one of the leveling Cylinder links to the ground Tap the pin the other direction and lower the opposite leveling link Note Perform this procedure with the boom in the Do not remove the pin stowed position 2 5 Attach a lifting strap from an overhead crane Note When removing a hose assembly or fitting to the rod end of the jib boom lift
143. erator knowledge may cause death or serious injury and property damage A WARNING Collision hazard Select a work site that is firm and level Component damage hazard If the machine must be towed do not exceed 2 mph 3 2 km h 1 Chock the steer wheels to prevent the machine from rolling 2 Centera lifting jack of ample capacity 20 000 Ibs 10 000 kg under the drive chassis between the non steer tires 3 Liftthe wheels off the ground and then place jack stands under the drive chassis for support Disengage the drive hubs by turning over the drive hub disconnect caps on each non steer wheel hub 1 brake disengaged position 2 brake engaged position 5 Manually rotate each non steer wheel Result Each non steer wheel should rotate with minimum effort 6 Re engage the drive hubs by turning over the hub disconnect caps Rotate each wheel to check for engagement Raise the machine remove the jack stands and lower the machine A WARNING Collision hazard Failure to re engage the drive hubs could result in death or serious injury and property damage Genie 36 Z 30 20N Z 30 20N RJ 2 34 22 2 34 22 Part No 139378 September 2015 Service Manual D 3 Check the Turntable Rotation Bearing Bolts Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first Maintaining proper torque
144. es manual A TEREX BRAND Terex South Dakota Inc USA 500 Oak Wood Road PO Box 1150 Watertown SD 57201 6150 605 882 4000 Genie UK The Maltings Wharf Road Grantham Lincolnshire NG31 6BH England 44 1476 584333 Instructions Use the operator s manual on your machine The Pre delivery Preparation consists of completing the Pre operation Inspection the Maintenance items and the Function Tests Use this form to record the results Place a check in the appropriate box after each part is completed Follow the instructions in the operator s manual If any inspection receives an N remove the machine from service repair and re inspect it After repair place a check in the R box Legend yes acceptable N no remove from service R 7 repaired Comments Pre delivery Preparation Y N R Pre operation inspection completed Maintenance items completed Function tests completed Model Serial number Date Machine owner Inspected by print Inspector signature Inspector title Inspector company September 2015 Service Manual morem wPP A dU This page intentionally left blank Genie BRAND Part No 139378 Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N 15 Maintenance Inspectio
145. ey switch to ground control 11 Test all machine functions from the ground controls Result All ground control functions should not operate 12 Using a suitable lifting device lift the test weight off the platform floor Result The platform overload indicator light should be off at both the ground and platform controls and the alarm should not sound Note There may be a 2 second delay before the overload indicator lights and alarm turn off 13 Test all machine functions from the ground controls Result All ground control functions should operate normally 14 Turn the key switch to platform control 15 Testall machine functions from the platform controls Result All platform control functions should operate normally Genie BRAND Part No 139378 Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N 53 Service Manual September 2015 Jib Boom Components 3 1 Jib Boom How to Remove the Jib Boom Note Perform this procedure with the boom in the stowed position Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications 1 Remove the platform 2 Remove the platform mounting weldment and the platform rotator See Repair procedure How to Remove the Platform Rotator 3 T
146. f the primary boom tube Place the extension tube on blocks for support Note During removal the overhead crane strap will need to be adjusted for proper balancing 7 Remove the external snap rings from the slave cylinder barrel end pivot pin 8 Use a soft metal drift and drive the slave cylinder barrel end pivot pin out 9 Remove the slave cylinder from the primary extension boom tube 10 Remove the external snap rings from the extension cylinder rod end pivot pins at the platform end of the extension tube Use a soft metal drift to remove the pins 11 Support and slide the extension cylinder out of the pivot end of the boom extension tube Place the extension cylinder on blocks for support Note During removal the overhead crane strap will need to be adjusted for proper balancing Primary Boom Components 4 3 Primary Boom Lift Cylinder The primary boom lift cylinder raises and lowers the primary boom The primary boom lift cylinder is equipped with a counterbalance valve to prevent movement in the event of a hydraulic line failure How to Remove the Primary Boom Lift Cylinder AWARNING Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended Note When removing a hose assembly or fit
147. ght Tighten the nut or fitting to the appropriate torque Refer to the appropriate torque chart in this section Operate all machine functions and inspect the hose fittings and related components to confirm there are no leaks 1 September 2015 JIC 37 fittings Align the tube flare hex nut against the nose of the fitting body body hex fitting and tighten the hex nut to the body hex fitting to hand tight approximately 30 in Ibs 3 4 Nm Using a permanent ink marker make a reference mark on one the flats of the hex nut and continue the mark onto the body of the hex fitting Refer to Illustration 1 41 9 Genie Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N Illustration 1 1 hex nut 2 reference mark 3 body hex fitting Part No 139378 September 2015 Service Manual ee Specifications 3 Working clockwise on the body hex fitting make a second mark with a permanent ink marker to indicate the proper tightening position Refer to Illustration 2 Note Use the JIC 37 Fitting table in this section to determine the correct number of flats for the proper tightening position Note The marks indicate the correct tightening positions have been determined Use the second mark on the body hex fitting to properly tighten the joint after it has been loosened Illustration 2 1 body hex fitting 2 reference mark 3 second mark 4 Tighten th
148. he terminal strip cover retaining pin fasteners Remove the cover supported ey uie overhead crane 13 Remove the terminal strip retaining fasteners Do not disconnect the wiring 22 Carefully lower the cylinder down through the secondary boom enough to access the 15x Remove the plastic plug in ds bulkiead ud hydraulic hoses Do not pinch the hoses access the secondary boom lift cylinder rod end pivot pin Component damage hazard 15 Remove the mounting fasteners from the ius Kod B 12 function manifold and slide the manifold to the side This will allow access to the hydraulic tank side barrel end pivot pin Genie Part No 139378 Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N 75 September 2015 Secondary Boom Components 23 Tag disconnect and plug the hydraulic hoses from the secondary boom lift cylinder Cap the fittings on the cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 24 Remove the cylinder through the top of the secondary boom AWARNING Crushing hazard The secondary boom lift cylinder could become unbalanced and fall when removed from the machine if not properly attached to the overhead crane 76 Z 30 20N Z 30 20N
149. hen the tire and wheel assembly 12 Lower the machine and remove the blocks 13 Torque the wheel lug nuts to specification Refer to Specifications Machine Torque Specifications Qai 1 1 1 1 1 92 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N Part No 139378 2015 Service Manual Non steer Axle Components 10 1 4 Set an ohmmeter to diode test mode Motor Controller Connect the leads from an ohmmeter to test each motor controller terminal combination The drive motor controller is located under the listed below and check the forward reverse non steer end drive chassis cover The drive motor bias diode test Con TONET cAn felonies ve Result All desired results must be within the malfunctions and display controller fault codes by flashing a LED at the ground controls and on the motor controller See the Fault Code section of this manual for a list of fault codes and additional information There are no adjustments needed on the drive joystick controller For further information or assistance consult the Genie Industries Service Department How to Test the Motor Controller Note Use the following procedure to test the motor controller If the motor controller is found to be faulty note which test failed and which fault code if any was present at the time of failure 1 Turn the key switch to the off position and specified range If any test has a result not within the specified rang
150. hop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended Note Perform this procedure with the boom in the stowed position Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications 1 Remove the platform 2 Remove the platform rotator Refer to Repair Procedure How to Remove the Platform Rotator 3 Remove the jib boom Refer to Repair Procedure How to Remove the Jib Boom 4 Models without rotating jib boom Remove the jib boom bellcrank Refer to Repair Procedure How to Remove the Jib Boom Bellcrank Models with rotating jib boom Remove the jib boom rotator Refer to Repair Procedure How to Remove the Jib Boom Rotator Genie 60 Z 30 20N Z 30 20N RJ 2 34 22 2 34 22 Part No 139378 September 2015 Service Manual Primary Boom Components 5 disconnect and cap the slave cylinder 12 Locate the cables from the primary boom hydraulic hoses at the union Plug the hoses cable track to the platform control box from the slave cylinder Number each cable and its entry location at Bodily injury h 456 the platform control box odily injury hazard Spraying A WARNING hydraulic oil
151. ht from the lower leveling link 45 46 47 48 49 50 Remove the mounting fasteners from the function manifold and slide the function manifold to the side This will allow access to the secondary boom lift cylinder barrel end pivot pin Remove the mounting fasteners from the auxiliary power unit Do not disconnect the electrical cables or hydraulic hoses Slide the auxiliary power unit to the side to access the other secondary boom lift cylinder barrel end pivot pin Remove the retaining fasteners from the secondary boom lift cylinder barrel end pivot pins Attach a lifting strap from an overhead crane to the lug on the rod end of the secondary boom lift cylinder Tag disconnect and plug the hydraulic hoses from the secondary boom lift cylinder Cap the fittings on the cylinder Bodily injury hazard Spraying PNW hazard The AWARNING hydraulic oil can penetrate and ene burn skin Loosen hydraulic stability j me connections very slowly to allow the oil pressure to dissipate during reassembly of he gradually Do not allow oil to machine the machine will squirt or spray become unstable and tip over A WARNING Crushing hazard The counterweight could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane Genie 72 Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N Part No 139378
152. ible hazards associated with using this machine They also provide users with operation and maintenance information An illegible decal will fail to alert personnel of a procedure or hazard and could result in unsafe operating conditions 1 Check to make sure that the operator s and safety manuals are present and complete in the storage container on the platform 2 Examine the pages of each manual to be sure that they are legible and in good condition Result The operator s manual is appropriate for the machine and all manuals are legible and in good condition Result The operator s manual is not appropriate for the machine or all manuals are not in good condition or is illegible Remove the machine from service until the manual is replaced Checklist A Procedures 3 Open the operator s manual to the decals inspection section Carefully and thoroughly inspect all decals on the machine for legibility and damage Result The machine is equipped with all required decals and all decals are legible and in good condition Result The machine is not equipped with all required decals or one or more decals are illegible or in poor condition Remove the machine from service until the decals are replaced 4 Always return the manuals to the storage container after use Note Contact your authorized Genie distributor or Genie if replacement manuals or decals are needed Genie BRAND Z 30 20N Z 30
153. ical Schematics Options eere 103 Power Cable Wiring 104 Drive Contactor Panel Wiring 105 Manifold and Limit Switch Wiring Diagram 108 LVI BCI Option Wiring Diagram 109 Charger Interlock 22 22 2 0 112 CTE Option Models e te Ee te 113 Hydraulic 115 Hydraulic rera re E DR ERROR 116 Genie Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N Part 139378 September 2015 TT EEE EE Table of Contents Electrical Schematics ANSI CSA AS 117 Electrical Schematic ANSI CSA AS before serial numbers Z30N10 121 19 Z34N10 8857 and 23410 77774 118 Ground Control Box Terminal Strip Wiring Diagram ANSI CSA AS before serial numbers 23010 12119 Z34N10 8857 and Z3410 7774 119 Ground Control Box Terminal Strip Wiring Diagram ANSI CSA AS before serial numbers 23010 12119 Z34N10 8857 and 23410 7774 122 Ground Control Box Switch Panel Wiring Diagram ANSI CSA AS before serial numbers Z30N10 12119 234 10 8857 and 23410 7774 123 Platform
154. ight direction until turntable stops against the rotation stop Observe the pressure reading on the pressure gauge Refer to Specifications Manifold Component Specifications 4 Turnthe machine off Hold the turntable relief valve s with a wrench and remove the cap item D 5 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Then install the relief valve cap A WARNING Tip over hazard Do not adjust the relief valve higher than specified 6 Repeatsteps 2 and 3 to confirm the relief valve pressure setting 7 Remove the pressure gauge Gaii 1 1 1 1 1 1 1 84 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N Part No 139378 September 2015 Service Manual r Manifolds 7 3 Jib Boom and Platform Jib Boom Rotate Manifold Components before serial numbers Z30N10 12102 Z30N10 RJ 12197 Z34N10 8838 and Z3410 7720 The jib boom platform rotate manifold is mounted to the jib boom Index Schematic Description tem Function Torque 1 Solenoid valve 3 position 4 way AA Jib boom up down 20 25 ft lbs 27 34 Nm 2 Solenoid valve 3 position 4 way AB Platform rotate left right 20 25 ft lbs 27 34 Nm 3 Solenoid valve 3 position 4 way AC Jib boom rotate left right 20 25 ft lbs 27 34 Nm 4 Flow regulator valve AD Platform rotate circuit 20 25 f
155. ight position until the platform is fully rotated to the right 2 Place a suitable container underneath the platform rotator 3 Open the top bleed screw on the rotator but do not remove it A WARNING Bodily injury hazard Spraying 5 Support the platform rotator with a suitable hydraulic oil can penetrate and lifting device Do not apply any lifting pressure burn skin Loosen hydraulic Sag connections very slowly to allow 6 Remove the pin retaining fasteners from the the oil pressure to dissipate jib boom and leveling links to platform rotator gradually Do not allow oil to pivot pins Do not remove the pins squirt or spray Genie 50 Z 30 20N Z 30 20N RJ 2 34 22 2 34 22 Part No 139378 September 2015 Service Manual 4 Move the function enable toggle switch to either side and hold the platform rotate toggle Switch to the left position until the platform is fully rotated to the left Continue holding the toggle switch until air stops coming out of the bleed screw Close the bleed screw A WARNING Crushing hazard Keep clear of the platform during rotation 5 Open the bottom bleed screw on the rotator but do not remove it A WARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 6 Move the function enable toggle switch to either side and hol
156. imary boom pivot pin Remove the primary boom pivot pin with a soft metal drift Carefully remove the primary boom assembly from the machine September 2015 How to Disassemble the Primary Boom Note Complete disassembly of the boom is only necessary if the outer or inner boom tubes must be replaced The extension cylinder can be removed without completely disassembling the boom Refer to Repair Procedure How to Remove the Extension Cylinder 1 Remove the primary boom Refer to Repair Procedure How to Remove the Primary Boom Place blocks under the extension cylinder for support Remove the retaining fasteners from the extension cylinder barrel end pivot pin Use a soft metal drift to remove the pin Remove and label the location of the wear pads from the top side of the boom tube at the platform end of the boom Note Pay careful attention to the location and amount of shims used with each wear pad A WARNING Crushing hazard The primary 5 Support the extension tube with an overhead boom could become unbalanced crane at the platform end of the boom and fall when removed from the machine if not properly attached AWARNING Crushing hazard The boom to the overhead crane extension tube could fall when removed from the boom if not properly supported Genie 62 Z 30 20N Z 30 20N RJ 2 34 22 2 34 22 Part No 139378 September 2015 Service Manual 6 Support and slide the extension tube out o
157. in Use a soft metal drift to remove the pin Genie Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N AWARNING September 2015 Carefully pull out and properly support the extension cylinder from the primary boom with a lifting strap from an overhead crane Crushing hazard The extension cylinder could fall when removed from the extension boom if not properly supported Component damage hazard Be careful not to damage the counterbalance valves on the primary boom extension cylinder when removing the cylinder from the primary boom Component damage hazard Hoses and cables can be damaged if the primary boom extension cylinder is dragged across them Note Note the length of the cylinder after removal The cylinder must be at the same length for installation Part No 139378 September 2015 Service Manual 4 5 Platform Leveling Master Cylinder The platform leveling master cylinder acts as a pump for the slave cylinder It is part of the closed loop hydraulic circuit that keeps the platform level through the entire range of primary boom motion The platform leveling master cylinder is located inside the upper mid pivot at the pivot end of the primary boom How to Remove the Platform Leveling Master Cylinder A WARNING Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in
158. ion Continued use of an improperly greased platform overload mechanism could result in the system not sensing an overloaded platform condition and will result in component damage 1 Locate the grease fittings on each pivot pin of the platform overload assembly 2 Thoroughly pump grease into each grease fitting Grease Specification Chevron Ultra duty grease EP NLGI 1 lithium based or equivalent Checklist C Procedures 2 Test the Platform Overload System if equipped Genie specifications require that this procedure be performed every 500 hours or six months whichever comes first OR when the machine fails to lift the maximum rated load Testing the platform overload system regularly is essential to safe machine operation Continued use of an improperly operating platform overload System could result in the system not sensing an overloaded platform condition Machine stability could be compromised resulting in the machine tipping over Note Perform this procedure with the boom fully retracted and in the stowed position and with the machine on a firm level surface 1 Remove all weight tools and equipment from the platform Note Failure to remove all weight tools and accessories from the platform will result in an inaccurate test 2 Turnthe key switch to platform controls and pull out the red Emergency Stop button to the on position at both the ground and platform controls Level the platform 3
159. itch on and activate each boom function toggle switch Note To conserve battery power test each function through a partial cycle Result All boom functions operate 4 Close the emergency power switch cover and secure the cover with a security tie if equipped Genie BRAND Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N 31 Part No 139378 September 2015 _ Checklist B Procedures 5 the key switch to platform controls At the platform controls break the security tie and lift the emergency power switch cover if equipped 7 Press down on the foot switch and simultaneously hold the emergency power switch on and activate each boom function Note To conserve battery power test each function through a partial cycle Result All boom functions operate 8 Close the emergency power switch cover and secure the cover with a security tie if equipped OS 32 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N Part No 139378 September 2015 Service Manual C 1 Grease the Platform Overload Mechanism if equipped Genie specifications require that this procedure be performed every 500 hours or six months whichever comes first Perform this procedure more often if dusty conditions exist Application of lubrication to the platform overload mechanism is essential to safe machine operat
160. itive chemistry When incompatible fluids are mixed insoluble materials may form and deposit in the hydraulic system plugging hydraulic lines filters control valves and may result in component damage Note Do not operate the machine when the ambient air temperature is consistently above 120 F 49 C Hydraulic Fluid Temperature Range 40 22 4 40 30 20 10 0 14 32 50 68 86 104 122 F 10 20 30 40 50 C Ambient air temperature 1 Chevron hydraulic oil 5606A 2 Petro Canada Environ MV 46 3 Hydrolube HP 5046D 4 Chevron Rando HD premium oil MV Genie BRAND Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N 3 Part No 139378 Service Manual September 2015 Specifications Chevron Rando HD Premium Oil MV Fluid Properties ISO Grade 32 Viscosity index 200 Kinematic Viscosity cSt 200 F 100 C 7 5 cSt 104 F 40 C 33 5 Brookfield Viscosity cP 4 F 20 C 1040 cP 22 F 30 C 3310 Flash point 375 F 190 C Pour point 58 F 50 C Maximum continuous operating 171 F 77 C temperature Note An hydraulic oil heating system is recommended when the ambient temperature is consistently below 0 F 18 C Note Do not operate the machine when the ambient temperature is below 20 F 29 C with Rando HD Premium MV Chevron 5606A Hydraulic Oil
161. l es 8 8 PO NC Tel 2 5 m 8 85 1 g E 55 2 p DAU CaP m 9 LO d 4 L H 9 2 1 4 OPTION BR 8 T 8 m Lo onu o 5 9 5 i 5 073 5 5 2 3 1 5 T He AD BK 9 Des 4 TS49 2 _WHIRD 2 RD o LABEL DESCRIPTION DP1 CR45 __ RELAY WORK LIGHTS OPTION 1 2 8 4 5 8 7 8 9 10 Ta P2 EMERGENCY STOP BUTTON P3 HORN BUTTON 6 GR BK DP1 DRIVE CONTROLLER BP1 BOOM FUNCTION SPEED CONTROLLER AUXILIARY TOGGLE SWITCH zl TS7 PLATFORM ROTATE TOGGLE SWITCH JIB BOOM UP DOWN TOGGLE SWITCH PLATFORM LEVEL TOGGLE SWITCH TS10 SECONDARY BOOM UP DOWN TOGGLE SWITCH 1511 PRIMARY BOOM UP DOWN TOGGLE SWITCH lo o lo b b lo o eo olo o o e TS12 TURNTABLE ROTATE TOGGLE SWITCH 9 I9 9 5 gp S oo 9 j2 18 Ble 8 E 8 BS E E 5 5 e y s e 8 8 8 5 8 8 m 8 Su E 5 8 1513 EXTEND RETRACT TOGGLE SWITCH 7 5 2m GG 3 E m Ble ess mi 2 amp 4 gt e Bg FM 2 5 2 5 eee 5 2 2 0 an i o
162. l pressure to dissipate gradually Do not allow oil to squirt or spray Genie BRAND Part No 139378 Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N 99 September 2015 Electrical Symbol Legend I cm z Ht FB Battery Coil solenoid or relay Horn or alarm Flashing beacon Gauge FA FS1 L3 1 25A Diode Hour meter LED Fuse with amperage Foot switch A BC N60 on 3 PULL IN HOLD Fuel or RPM solenoid T circuits connect Limit Switch Power relay Coil with suppression l TB21 2 15 T circuits connect at Circuits crossing no Quick disconnect Circuit breaker with terminal connection terminal amperage mow Eo UT TGROUND 25 5 6 we gt SR 00000 0 E 2 Key switch Toggle switch DPDT Toggle switch SPDT Tilt sensor T 5100 Horn Dutton nomi Emergency step button Resistor with ohm value Battery seperator Gauge sending unit open normally closed SW3 di SW1 Sw2 CR4 pues N C N O Oil temperature switch Coolant temperature Oil pressure switch Control relay contact Diode starting aid glow normally open Switch
163. lashing 5 Press down the foot switch Move the primary boom switch to the down position hold for a moment and then release it Move the secondary boom switch to the down position hold for a moment and then release it Move the jib boom switch to the down position hold for a moment and then release it Result The descent alarm should sound when each control switch is held down 6 Press down the foot switch Move the drive control handle off center hold for a moment and then release it Move the drive control handle off center in the opposite direction hold for a moment and then release it Result The travel alarm should sound when the drive control handle is moved off center in either direction Genie BRAND Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N 29 Part No 139378 Service Manual September 2015 Checklist B Procedures B 12 Test the Turntable Rotation Stop Note Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first The turntable is capable of rotating the boom 359 degrees and is stopped midpoint between the steer wheels by the rotation stop Detecting a rotation stop malfunction is essential to safe operation and good machine performance If the turntable rotates past the rotation stop component damage may result 1 the key switch to platform controls and pull out the red Emergency Stop buttons to the
164. ld fall when the pin is removed if not properly supported by the overhead crane 54 Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N Part No 139378 September 2015 Service Manual 9 Remove the pin retaining fasteners from the jib boom lift cylinder rod end pivot pin Do not remove the pin 10 Models without rotating jib boom Remove both of the jib boom leveling links from the bell crank Models with rotating jib boom Remove both of the jib boom leveling links from the jib boom rotator 11 Attach a lifting strap from an overhead crane to the rod end of the jib boom lift cylinder 12 Models without rotating jib boom Use a soft metal drift to remove the jib boom lift cylinder rod end pivot pin Remove the jib boom lift cylinder from the bell crank Models with rotating jib boom Use a soft metal drift to remove the jib boom lift cylinder rod end pivot pin Remove the jib boom lift cylinder from the jib boom rotator A WARNING Crushing hazard The jib boom lift cylinder may become unbalanced and fall when it is removed from the machine if it is not properly supported by the overhead crane Jib Boom Components 3 2 Jib Boom Bell Crank models without rotating jib boom How to Remove the Jib Boom Bell Crank Note Perform this procedure with the boom in the stowed position Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connection
165. lia Pty Ltd Phone 461 7 3456 4444 Fax 61 7 3375 1002 Genie China Phone 86 21 53853768 Fax 86 21 53852569 Genie Sinapore Phone 65 67533544 Fax 65 67533544 Genie Japan Phone 81 3 6436 2020 Fax 81 3 5445 1231 Genie Korea Phone 82 2 558 7267 Fax 82 2 558 3910 Genie U K Phone 0044 1476 584 333 Fax 0044 1476 584 330 Genie Brasil Phone 55 11 4082 5600 Fax 55 22 4082 5630 Genie Mexico City Phone 52 55 5666 5242 Fax 52 55 5666 3241 Genie Holland Phone 31 183 581 102 Fax 31 183 581 566
166. ltimeter and connect the white red wire to the diode on the black red wire Boom function speed controller specifications Threshold 0 28A controller turned to creep Max out 0 65A controller turned to 9 Ramp rate Genie Z 30 20N Z 30 20N RJ 2 34 22 2 34 22 2 seconds Part No 139378 September 2015 Service Manual 2 1 Platform Leveling Slave Cylinder The slave cylinder and the rotator pivot are the two primary supports for the platform The slave cylinder keeps the platform level through the entire range of boom motion It operates in a closed circuit hydraulic loop with the master cylinder The slave cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure How to Remove the Platform Leveling Slave Cylinder Note Before cylinder removal is considered bleed the slave cylinder to be sure there is no air in the closed loop Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications 1 Extend the boom until the slave cylinder barrel end pivot pin is accessible 2 Raisethe boom slightly and place blocks under the platform for support Lower the boom until the platform is resting on the blocks Platform Components
167. ly attached to the overhead crane Genie BRAND Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N 67 Part No 139378 September 2015 Secondary Boom Components 5 9 15 SS w j Secondary Boom components 6 lower compression arm 1 upper pivot 7 turntable pivot 2 upper compression arm 8 counterweight Z 30N Z 30N RJ 3 mid pivot 9 upper secondary boom 4 compression link 5 lower secondary boom Gaii 1 68 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N Part No 139378 September 2015 Service Manual Secondary Boom Components 5 1 5 Remove the wire loom from the cables at the Secondary Boom How to Disassemble the Secondary Boom AWARNING Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended Follow the disassembly steps to the point required to complete the repair Then re assemble the secondary boom by following the disassembly steps in reverse order Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Sp
168. m Drive hubs 48 1 24 5 fl oz 0 72 liters nee M wheels Z 34 22 57 1 24 5 fl oz 0 72 liters Drive hub type 90 multipurpose hypoid gear oil Tire ply rating 12 API service classification GL5 Tire weight new foam filled 175 Ibs minimum 79 kg Overall tire diameter 28 in For operational specifications refer to the 71cm Operator s Manual Wheel diameter 14 5in Continuous improvement of our products is 37cm Genie policy Product specifications are Wheel width 7Tin subject to change without notice or obligation 18 cm Ganie Part No 139378 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N 1 Service Manual September 2015 Specifications Performance Specifications Z 30 20N and Z 30 20N RJ Performance Specifications Z 34 22 and Z 34 22N Drive speed maximum Stowed position 4 5 mph 7 2 km h 40 ft 6 0 sec 12 2 m 6 0 sec Drive speed maximum Stowed position 4 5 mph 7 2 km h 40 ft 6 0 sec 12 2 6 0 sec Boom raised or extended 0 6 mph1 km h40 ft 42 sec12 2 42 sec Boom raised or extended 0 6 mph1 km h40 ft 42 sec12 2 m 42 sec Braking distance maximum Braking distance maximum High range on paved surface 2 to 4 ft 0 6 to 1 2m High range on paved surface 2 to 4 ft 0 6 to 1 2m Gradeability See Operator s Manual Gradeability See Operator s Manual Boom function speeds maximum from platform controls with rated load secu
169. m the machine How to Bleed the Jib Boom Rotator Note This procedure will require two people 1 o 56 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N Part No 139378 Turn the key switch to ground controls and pull out the red Emergency Stop buttons to the on position at both the ground and platform controls September 2015 Connect a clear hose to the top bleed valve Place the other end of the hose in a container to collect any drainage Open the top bleed Service Manual Jib Boom Components Fully rotate the jib boom to the left and continue holding the jib boom rotate toggle Switch until air stops coming out of the bleed valve but do not remove it valve Immediately release the platform rotate toggle switch and close the bleed valve Crushing hazard Keep hands A WARNING and head clear of the platform pivot weldment during rotation 6 Rotate the jib boom to the right until the jib boom is centered 2 7 Connect the clear hose to the bottom bleed valve and open the valve 8 8 Rotate the jib boom to the right and continue holding the platform rotate toggle switch until air stops coming out of the bleed valve Crushing hazard Keep hands AWARNING and head clear of the jib boom during rotation 1 top bleed valve 2 clear hose 3 container 4 bottom bleed valve 9 Close the bleed valve and remove the hose 3 Move and hold the function enable toggle n Switch to eith
170. mage hazard Be sure to open the two hydraulic tank valves and prime the pump after installing the pump Genie BRAND Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N 77 139378 Service Manual Manifolds 7 1 Function Manifold Components The function manifold is locate behind the ground controls turntable cover September 2015 _______ ___________ ____ ____ ___ __ ns Description Function Torque 1 Solenoid valve 3 position 4 way A Platform level up down 20 25 ft lbs 27 34 Nm 2 Counterbalance valve Platform level down 20 25 ft lbs 27 34 Nm 3 Counterbalance valve C Platform level up 20 25 ft lbs 27 34 Nm 4 Relief valve 1100 psi 75 8 bar D Turntable rotate left right 30 35 ft Ibs 41 47 Nm 5 Relief valve 1600 psi 110 bar E Secondary boom down 20 25 ft lbs 27 34 Nm 6 Relief valve 1600 psi 110 bar F Primary boom down 20 25 ft lbs 27 34 Nm 7 Relief Valve 1800 psi 124 bar G Primary boom extend 20 25 ft lbs 27 34 Nm Z 30 N RJ 8 Proportional solenoid valve H System flow regulating circuit 30 35 ft lbs 41 47 Nm 9 Check valve Brake circuit 10 12 ft lbs 14 16 Nm 10 Solenoid valve 3 position 4 way J Steer left right 20 25 ft lbs 27 34 Nm 11 Solenoid valve 3 position 4 way K Primary boom extend retract 20 25 ft lbs 27 34 Nm 12 Pressure switch Brake circuit 13 Solenoid valve N C poppet M Brake circuit 20 25 ft lbs 27 34 Nm
171. maintained and ready for use Keep work surfaces clean and free of debris that could get into machine components and cause damage 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 Be sure that your workshop or work area is properly ventilated and well lit September 2015 lt lt Table of Contents Introduction hiienipibDnm ii Important Information eu teen rta ii Find a Manual for this ii Revision iii Serial Number Legend tnde red eh tea V Section 1 CIA fte vi General Safety da dota eot set vi Section 2 5 EX Ra an ER rta LEER Rud 1 Machine 1 Performance Specifications sss 2 Hydraulic Specification aa etate 3
172. mbers Z30N10 12119 Z34N10 8857 and Z3410 7774 C29JSH September 2015 before serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 Electrical Schematic CE Service Manual 1 1 T 1 E 1 zz 1 H 2 5 5 8 gi g E gi JE E 8 5558 8 T 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 I 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 EE 8 DUTE BKWH BKWHC2B 12 16 3 ES 5 t QD wg mes 1 1 VAST Pa E 9 129 DRIVE LIGHT 1 1 Ygv OPTION 1 zE 288 gts P LAM M 1 2 oe m ES 85 1 1 1 1 1 P48LPB WH RD G1P 9 RAZBATORAD 1 8 WHIRD C2B 9 7 WH 19 2 1 1 1 1 1 1 1 1 1 1 1
173. meters 45 seconds If the machine is allowed to drive faster than specification the machine could become unstable and will tip over Note Additional troubleshooting of the fault codes may by accomplished by using the hand held pendant motor controller programmer Genie part number 128551 Note When using the hand held pendant motor controller programmer the M1 MAX SPEED needs to be set to 33 If needed adjust the M1 MAX SPEED higher or lower to achieve the maximum raised drive speed of 0 6 mph 1Km h 40 feet 45 seconds 12 2 meters 45 seconds The controller status indicator light will flash a fault code to aid in troubleshooting This indicator light is mounted on the tilt level sensor mounting bracket located behind the cover on the ground controls side Fault codes are two digits The controller status indicator light will blink the first digit of a two digit code pause for 1 second and then blink the second digit There will be a 2 second pause between codes Fault Codes For example the indicator light blinks 4 consecutive times pauses for 1 second and then blinks 1 time That would indicate Fault Code 41 Breakgy 0 EN 10 AMP is ight Genie BRAND Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N 95 Part No 139378 September 2015 _____ ___ __ ___________ ____ ___ ___ Fault Codes Fault Code Chart
174. n Report September 2015 Model Checklist A Checklist C N 1 Inspect the manuals C 1 Grease platform Serial number and decals overload if equipped 2 Pre operation C 2 Test platform Date inspection overload if equipped A 3 Function tests Checklist D N Hour meter Perform after 40 hours 0 1 Boom wear pads A 4 30 service D 2 Free wheel configuration Perform every 100 hours D 3 Turntable bearing Inspected by print A 5 Grease rotation bolts bearing Inspector signature D 4 Drive hub oil Perform after 150 hours DS perso titie D 5 Hydraulic filters 1 t A 6 Drive hub oil i r D 6 Turntable bearing Checklist B YNR wear Instructions B 1 Battery Checklist E YNR e Make copies of this report to use for Be E 1 Hydraulic oil each inspection B 3 Tires and wheels E 2 Wheel bearings Select the appropriate checklist s for Brake configuration the type of inspection s to perform Comments Daily or every 8 hours A 5 Drive hub oil Quarterly or every A B B 6 Ground control 250 hours override 7 8 Drive brakes Semi annually or Platform leveling every 500 hours Annually or 0 B 9 Drive speed stowed 1000 hours B 10 Drive s
175. nal strip cover retaining fasteners Remove the cover Remove the terminal strip retaining fasteners Do not disconnect the wiring Remove the plastic plug in the bulkhead to access the secondary boom lift cylinder rod end pivot pin Remove the pin retaining fastener from the rod end of the secondary boom lift cylinder Use a soft metal drift to remove the pin through the access holes in the bulkheads Secure the cylinder from moving Remove the pin retaining fastener from the lower pivot pin on the compression link Use a Soft metal drift to remove the pin Genie BRAND Part No 139378 Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N 71 Service Manual September 2015 Secondary Boom Components 40 41 42 Attach a lifting strap from an overhead crane to the upper secondary boom Remove the pin retaining fastener from the mid pivot to upper secondary boom pivot pin Use a soft metal drift to remove the pin Remove the upper secondary boom with compression link from the machine CAUTION Crushing hazard The upper 43 secondary boom with compression link could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane Z 30N and Z 30N RJ Remove the mounting fasteners from the counterweight attached to the lower leveling link Z 30N and Z 30N RJ Attach a lifting strap from an overhead crane to the counterweight Remove the counterweig
176. nie Z 30 20N Z 30 20N RJ 2 34 22 2 34 22 September 2015 Note the reading on the dial indicator Result The measurement is less than 0 055 inch 1 4 mm The bearing is good Result The measurement is more than 0 055 inch 1 4 mm The bearing is worn and needs to be replaced Fully retract the primary boom Raise the primary and secondary booms to full height Visually inspect the dial indicator to be sure the needle returns to the zero position Remove the dial indicator and rotate the turntable 90 Repeat steps 4 through 9 until the rotation bearing has been checked in at least four equally spaced areas 90 apart Lower the primary and secondary booms to the stowed position and turn the machine off Remove the dial indicator from the machine Part No 139378 September 2015 1 Test Replace the Hydraulic Oil Genie specifications require that this procedure be performed every 2000 hours or every two years whichever comes first Perform this procedure more often if dusty conditions exist Replacement or testing of the hydraulic oil is essential for good machine performance and service life Dirty oil and a clogged suction strainer or hydraulic filters may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require oil changes to be performed more frequently Note Before replacing the hy
177. nual Fault Codes Fault Code Chart Fault Code Programmer Condition Possible Causes Solution Diagnostic Display 21 THROTTLE FAULT 1 Machine will not drive Open in wht red wire Consult Genie Product 32 at pin 14 or Support red wht wire 29 at pin 16 on the motor controller going from drive joystick to pins 14 and 16 at the motor controller OR pin 14 is internally shorted to power or ground OR the potentiometer on the drive joystick is defective THROTTLE FAULT 2 Machine will not drive Pin 14 wht red 32 is Consult Genie Product shorted to power or Support ground OR the potentiometer on the drive joystick is defective 31 CONT DRVR OC Machine will not drive Main contactor PR1 Replace main coil defective OR brake contactor PR1 or brake release relay release relay CR5 OR CR5 defective replace the motor controller 32 MAIN CONT WELDED Machine will not drive Main contactor PR1 Consult Genie Product contacts stuck closed Support OR grn wire at pin 17 on motor controller shorted to ground OR open in motor armature wiring OR motor controller has an internal short to ground 33 PRECHARGE FAULT Machine will not drive External short between Repair short between terminal on motor B terminal on motor controller and ground controller and ground OR motor controller is OR replace motor defective controller Note Short can be on any part of circuit connected to the
178. on position at both ground and platform controls 2 Rotate the turntable to the left as far as it will go Result Movement should stop when the primary boom reaches midpoint between the steer tires 3 Rotate the turntable to the right as far as it will go Result Movement should stop when the primary boom reaches midpoint between the steer tires B 13 Check the Electrical Contactors Note Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining the electrical contactors in good condition is essential to safe machine operation Failure to locate a worn or damaged contactor could result in an unsafe working condition and component damage 1 Remove the drive chassis cover from the non steer end of the machine and locate the electrical contactors mounted on the electrical component mounting panel 2 Visually inspect the contact points of each contactor for the following items e Excessive burns e Excessive arcs Excessive pitting A WARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Note Replace the contactors if any damage is found Genie 30 Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N Part No 139378 September 2015 B 14 Perform Hydraulic Oil Analysis Genie specificati
179. onent damage may also result if problems are not discovered and repaired in a timely fashion A WARNING Bodily injury hazard An over inflated tire can explode and could cause death or serious injury A WARNING Tip over hazard Do not use temporary flat tire repair products Note The tires on some machines are foam filled and do not need air added to them 1 Check all tire treads and sidewalls for cuts cracks punctures and unusual wear 2 Check each wheel for damage bends cracked welds 3 Check each lug nut for proper torque Refer to Specifications Machine Specifications 4 Check the pressure in each air filled tire Genie BRAND Part No 139378 Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N 23 Service Manual September 2015 Checklist B Procedures B 4 Confirm the Proper Brake Configuration Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Proper brake configuration is essential to safe operation and good machine performance Hydrostatic brakes and hydraulically released spring applied individual wheel brakes can appear to operate normally when they are actually not fully operational 1 Check each drive hub disconnect cap to be sure it is in the engaged position B 1 brake disengaged position 2 brake engaged position B 5 Check the Drive Hub Oil Level and Fastener Torque Genie specifications requi
180. ons require that this procedure be performed every 250 hours or quarterly whichever comes first Replacement or testing of the hydraulic oil is essential for good machine performance and service life Dirty oil and a clogged suction strainer may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require oil changes to be performed more often For hydraulic oil specifications refer to Specifications Hydraulic Specifications Note Before replacing the hydraulic oil the oil may be tested by an oil distributor for specific levels of contamination to verify that changing the oil is necessary If the hydraulic oil is not replaced at the two year inspection test the oil quarterly Replace the oil when it fails the test Refer to Maintenance Procedure Test or Replace the Hydraulic Oil Checklist B Procedures B 15 Test the Emergency Power System Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Testing the emergency power system regularly is essential to safe machine operation if the primary power source fails 1 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 2 Atthe ground controls break the security tie and lift the emergency power switch cover if equipped Simultaneously hold the emergency power sw
181. oom to a horizontal position 2 Extend the primary boom until the primary boom extension cylinder rod end pivot pin is accessible in the primary boom extension tube Genie BRAND Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N 65 Part No 139378 Primary Boom Components A WARNING 10 66 Remove the external snap rings from the extension cylinder rod end pivot pins Use a soft metal drift to remove the pins Remove the counterweight cover fasteners Remove the counterweight cover from the machine Raise the secondary boom until the master cylinder rod end pivot pin is accessible Remove the primary boom extend drive limit switch from the pivot end of the primary boom Do not disconnect the wiring Remove the retaining fastener from the master cylinder rod end pivot pin Use a soft metal drift to remove the pin Manually retract the master cylinder and push it toward the platform end of the boom to obtain enough clearance for extension cylinder removal Tag disconnect and plug the primary boom extension cylinder hydraulic hoses Cap the fittings on the cylinder Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Remove the retaining fastener from the extension cylinder barrel end pivot p
182. ot to upper secondary compression arm pivot pins Use a soft metal drift to remove the pins Swing the compression arms down and out of the way Secure them from moving Remove the pin retaining fasteners from the upper pivot to the upper secondary boom pivot pin Use a soft metal drift to remove the pin Carefully remove the entire primary boom assembly from the machine primary boom assembly jib boom assembly platform master cylinder primary lift cylinder and upper pivot Crushing hazard The primary boom assembly could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane Do not remove the assembly from the machine until it is properly balanced Note During removal the overhead crane strap will need to be adjusted for proper balancing 26 27 28 Genie Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N Place the entire assembly onto a structure capable of supporting it Remove the pin retaining fasteners from the upper secondary compression arm pivot pins Do not remove the pins Position a lifting strap from an overhead crane at the center of the control box side upper secondary compression arm Part No 139378 A WARNING A WARNING CAUTION September 2015 Service Manual Secondary Boom Components 29 Use a soft metal drift to remove the upper secondary boom compression arm pivot pins and remove the compression arm from the ma
183. own and allowed to settle between each adjustment Note There may be a 2 second delay before the platform overload indicator lights and alarm responds 7 Move the platform up and down by hand so it bounces approximately 2 5 to 5 cm 1 to 2 inches Allow the platform to settle Result The overload indicator lights are off and the alarm does not sound Proceed to step 8 Result The overload indicator lights flashing at the platform and ground controls and the alarm is sounding Repeat this procedure beginning with step 5 Note There may be a 2 second delay before the platform overload indicator light and alarm responds 8 Add an additional 10 Ib 4 5 kg test weight to the platform Result The overload indicator light is flashing at both the ground and platform controls and the alarm is sounding Proceed to step 9 amp Result The overload indicator light is off at both the ground and platform controls and the alarm does not sound Remove the additional 10 Ib 4 5 kg test weight Repeat this procedure beginning with step 6 Note There may be a 2 second delay before the platform overload indicator light and alarm responds Genie 52 Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N Part No 139378 September 2015 Service Manual Platform Components 9 Testall machine functions from the platform controls Result All platform control functions should not operate 10 Turn the k
184. peed raised Two yearor A B C D E B 11 Alarm package every ___________ 2000 hours B 12 Turntable rotation Place a check in the appropriate box ___ stop after each inspection procedure is B 13 Electrical contactors completed Use the step by step procedures in B 14 this section to learn how to perform B 15 Emergency power these inspections system 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 Genie BRAND 16 Z 30 20N Z 30 20N RJ 2 34 22 2 34 22 Part No 139378 September 2015 Service Manual A 1 Inspect the Manuals and Decals Genie specifications require that this procedure be performed every 8 hours or daily whichever comes first Maintaining the operator s and safety manuals in good condition is essential to safe machine operation Manuals are included with each machine and should be stored in the container provided in the platform An illegible or missing manual will not provide safety and operational information necessary for a safe operating condition In addition maintaining all of the safety and instructional decals in good condition is mandatory for safe machine operation Decals alert operators and personnel to the many poss
185. ptember 2015 Platform Components 5 Move the platform up and down by hand so it bounces approximately 2 5 to 5 cm 1 to 2 inches Allow the platform to settle Result The overload indicator lights are off and the alarm does not sound Proceed to step 6 Result The overload indicator lights are flashing at the platform and ground controls and the alarm is sounding Slowly tighten the load spring adjustment nut in a clockwise direction in 10 increments until the overload indicator light turns off and the alarm does not sound Proceed to step 8 Note The platform will need to be moved up and down and allowed to settle between each adjustment Note There may be a 2 second delay before the platform overload indicator light and alarm responds 6 Move the platform up and down by hand so it bounces approximately 2 5 to 5 cm 1 to 2 inches Allow the platform to settle Result The overload indicator lights are off at the platform and ground controls and the alarm does not sound Slowly loosen the load spring adjustment nut in a counterclockwise direction in 10 increments until the overload indicator light flashes at both the platform and ground controls and the alarm sounds Proceed to step 7 amp Result The overload indicator lights are flashing at the platform and ground controls and the alarm is sounding Repeat this procedure beginning with step 5 Note The platform will need to be moved up and d
186. r lights Illustration 1 should turn off at both the ground and platform controls and the alarm should not sound Result The platform overload indicator lights should be off at both the ground and platform Note There may be an 2 second delay before the controls and the alarm should not sound overload indicator lights and alarm turn off 6 additional weight to the platform that is 11 Test all machine functions from the ground equal to but does not exceed 159 of the controls WEE RI E 2 ins 22d Result All ground control functions should weight Refer to the machine serial plate operate normally Result The platform overload indicator lights TT should be flashing at both the ground and 1z 22 4 platform controls and the alarm should sound 9 Note There be a 2 second delay before the overload indicator lights flash and the alarm sounds Genie 34 Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N Part No 139378 September 2015 D 1 Check the Boom Wear Pads Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first Maintaining the boom wear pads in good condition is essential to safe machine operation Wear pads are placed on boom tube surfaces to provide a low friction replaceable wear pad between moving parts Improperly shimmed wear pads or continued use of extremely worn wear pads may result in
187. rd The primary boom lift cylinder could become unbalanced and fall if not properly supported by the lifting device 16 Attach an overhead crane or similar lifting device to the lug on the rod end of the primary boom lift cylinder Carefully loosen the straps and allow the primary boom lift cylinder to slowly swing down 17 Carefully remove the cylinder from the machine AWARNING Crushing hazard The primary boom lift cylinder could become unbalanced and fall if not properly supported by the lifting device Primary Boom Components 4 4 Primary Boom Extension Cylinder The primary boom extension cylinder extends and retracts the primary boom extension tube The primary boom extension cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure How to Remove the Primary Boom Extension Cylinder AWARNING Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications 1 Raise the primary b
188. re that this procedure be performed every 250 hours or quarterly whichever comes first Failure to maintain proper drive hub oil levels may cause the machine to perform poorly and continued use may cause component damage 1 Drive the machine to rotate the hub until the plugs are located one on top and the other at 90 degrees 1 drive hub plugs 2 Remove the plug located at 90 degrees and check the oil level Result The oil level should be even with the bottom of the plug hole Genie 24 Z 30 20N Z 30 20N RJ 2 34 22 2 34 22 Part No 139378 September 2015 Service Manual 21 Checklist B Procedures 3 If necessary remove the top plug and add oil B 6 until the oil level is even with the bottom of the side puc fale Test the Ground Control Override Genie specifications require that this procedure be A performed every 250 hours or quarterly whichever Check the torque of the drive hub mounting comes first bolts Refer to Specifications Machine A T Specifications A properly functioning ground control override is essential to safe machine operation The ground 6 Repeat this procedure for each drive hub control override function is intended to allow ground personnel to operate the machine from the ground controls whether or not the Emergency Stop button on the platform controls is in the on or off position This function is particularly useful if the operator
189. red to platform Boom function speeds maximum from platform controls with rated load secured to platform Jib boom up 19 to 23 seconds Jib boom up 20 to 24 seconds Jib boom down 17 to 21 seconds Jib boom down 18 to 22 seconds Jib boom rotate 180 13 to 17 seconds Primary boom up 16 to 22 seconds Primary boom up 14 to 22 seconds Primary boom down 13 to 20 seconds Primary boom down 12 to 20 seconds Primary boom extend 11 to 15 seconds Primary boom extend 15 to 19 seconds Primary boom retract 13 to 17 seconds Primary boom retract 10 to 14 seconds Secondary boom up 15 to 22 seconds Secondary boom up 11 to 18 seconds Secondary boom down 11 to 18 seconds Secondary boom down Turntable rotate 355 7 to 15 seconds 62 to 68 seconds Turntable rotate 355 Platform rotate 180 62 to 68 seconds 5 to 11 seconds Platform rotate 180 5 to 11 seconds Platform level up 14 to 19 seconds Platform level up 14 to 19 seconds Platform level down 13 to 18 seconds Platform level down 13 to 18 seconds Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice or obligation Genie Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N Part No 139378 September 2015 Service Manual Hydraulic Specific
190. rs A B Semi annually or every 500 hours A B C Annually or every 1000 hours A B C D Two year or every 2000 hours A B C Dt E Maintenance Inspection Report The maintenance inspection report contains checklists for each type of scheduled inspection Make copies of the Maintenance Inspection Report to use for each inspection Maintain completed forms for a minimum of 4 years or in compliance with your employer jobsite and governmental regulations and requirements Genie BRAND Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N 13 Part No 139378 September 2015 O E cc Pre Delivery Preparation Report Fundamentals It is the responsibility of the dealer to perform the Pre delivery Preparation The Pre delivery Preparation is performed prior to each delivery The inspection is designed to discover if anything is apparently wrong with a machine before it is put into service A damaged or modified machine must never be used If damage or any variation from factory delivered condition is discovered the machine must be tagged and removed from service Repairs to the machine may only be made by a qualified service technician according to the manufacturer s specifications Scheduled maintenance inspections shall be performed by qualified service technicians according to the manufacturer s specifications and the requirements listed in the responsibiliti
191. s PT severe por LW mE 2 BKSP BKont BEEN PROBAT WH EK CBIREV C185 C49 5 CH REVERSE TRANTRAT GRAWH CRS 19 GRANH SP LIFT PUMP Paw S ol FORWARD C4B 7 19 GRAWHMH LIFT PUMP RDW 049 3 CH 2 WIRE POT ORIRD 8 OR RD C4B 4 16 OR RD CRS DRIVE ENABLE 16 mm mnm CAM OR BK 4 3 15 ORBK MH PLATFORM LEVEL DOWN CISPLD GP K 18 57 PLATFORM RIGHT OR 14 PLATFORM LEVEL UP m ihi menm a BE 1 BLAWH CH ea BLAD DRIVE ENABLE LIGHT BL K C3B 11 T1 BUBKMH BLBKSP SECONDARY BOOM DOWN C11SBD sns ERN nup aa we BL 10 10 BLMH BL SP SECONDARY BOOM UP C10SBU RD WH COBAT 86 CR2 86 48V RELAY COIL POWER BKMWH Cob 8 8 BKWH MH BKANH P PRIMARY BOOM RETRACT BLANH 2 082 8 PLATFORM OVERLOAD INPUT BK O3B7 7 BK SP PRIMARY BOOM EXTEND _ G7PBE num 2284 L450 PLATFORM OVERLOAD ALARM WH RD C38 6 8 WHRD MH WHIRD SP FUNCTION SPEED CONTROL PRRD ae Cd mE dB POWER WHIBK 8 5 B WHIBK MH WHIBK SP TURNTABLE ROTATE RIGHT 5 fone nue nomm p URE RoE WH 4 4 WH MH TURNTABLE ROTATE LEFT CATAL RD BK 638 2 2 RD BKMH RD BK SP PRIMARY BOOM DOWN _ C2PBD RD C9B 1 1 RD 8P PRIMARY BOOM UP 1 D C2B 12 WH
192. s first Replacing the drive hub oil is essential for good machine performance and service life Failure to replace the drive hub oil at yearly intervals may cause the machine to perform poorly and continued use may result in component damage 1 Select the drive hub to be serviced Drive the machine until one of the two plugs is at the lowest point 2 Remove the plugs and drain the oil into suitable container 3 Drive the machine until one of the two plugs is at the highest point 1 drive hub plugs 4 Fillthe hub until the oil level is even with the bottom of the lowest plug hole Refer to Specifications Machine Specifications 5 Repeat this procedure for each drive hub D 5 Replace the Hydraulic Tank Return Filter Element Note Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first Perform this procedure more often if dusty conditions exist Replacement of the hydraulic return filter element is essential for good machine performance and service life A dirty or clogged filter element may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require that the filter element be replaced more often CAUTION Bodily injury hazard Beware of hot oil Contact with hot oil may cause severe burns 1 Locate the hydraulic return filter housing on top of the hydraulic tank 2 Cleanthe area around
193. s must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications 1 Remove the jib boom Refer to Repair Procedure How to Remove the Jib Boom 2 Support and secure the jib boom bell crank to an appropriate lifting device 3 Remove the pin retaining fasteners from the slave cylinder rod end pivot pin Do not remove the pin 4 Place a block of wood under the platform leveling slave cylinder for support Protect the cylinder rod from damage 5 Remove the pin retaining fasteners from the jib boom bell crank at the extension boom Use a soft metal drift to remove the pin 6 Usea soft metal drift to remove the slave cylinder rod end pivot pin 7 Remove the jib boom bell crank from the extension boom A WARNING Crushing hazard The jib boom bellcrank may become unbalanced and fall if it is not properly supported when it is removed from the machine Genie BRAND Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N 55 Part No 139378 Service Manual September 2015 Jib Boom Components 3 3 Jib Boom Rotator models with rotating jib boom The platform rotator is a hydraulically activated helical gear assembly used to rotate the jib boom 160 degrees How to Remove the Jib Boom Rotator Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torque
194. significant component damage Dealer service is strongly recommended Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications 1 Rotate the turntable to either side until the boom is centered between the steer and non steer tires 2 Raise the primary boom to full height Do not extend it 3 Swing out the battery pack that is directly below the secondary boom lift cylinder 4 Disconnect the battery packs from the machine 5 Open the hydraulic tank side turntable cover 6 Tag and disconnect the power cables on the auxiliary power unit AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 7 Close the hydraulic tank shutoff valve Tag and disconnect and plug the hydraulic hose from the hydraulic tank shutoff valve AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 8 Open the valve on the hydraulic tank and drain the oil into a container of suitable capacity Refer to Specifications Machine Specifications A CAUTION Bodily injury haz
195. t lbs 27 34 Nm 0 3 1 14 L min 5 Orifice plug 0 025 inch 0 64 mm AE Jib boom rotate circuit located under plug 15 ZA 92 gt OS 22 87 UE N gt Models with rotating jib boom Models without rotating jib boom Genie BRAND Part No 139378 Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N 85 Service Manual September 2015 ______ _____ ______ ____ ____ ___ __ Manifolds Jib Boom and Platform Jib Boom Rotate Manifold Components from serial numbers Z30N10 12102 Z30N10 RJ 12197 Z34N10 8838 and Z3410 7720 The jib boom platform rotate manifold is mounted to the jib boom Index Schematic No Description item Function Torque 1 Solenoid valve 3 position 4 way AA Jib boom up down 20 25 ft lbs 27 34 Nm 2 Solenoid valve 3 position 4 way AB Platform rotate left right 20 25 ft Ibs 27 34 Nm 3 Solenoid valve 3 position 4 way AC Jib boom rotate left right 20 25 ft lbs 27 34 Nm 4 Flow regulator valve AD Platform rotate circuit 20 25 ft lbs 27 34 Nm 0 3 gpm 1 14 L min 5 Orifice plug 0 025 inch 0 64 mm AE Jib boom rotate circuit located under plug WMA Wa AP 4 Models with rotating jib Models without rotating jib O 86 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 2
196. t the Battery Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Proper battery condition is essential to good engine and machine performance and operational safety Improper fluid levels or damaged cables and connections can result in engine and component damage and hazardous conditions A WARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Bodily injury hazard Batteries contain acid Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water A WARNING Note Fully charge the batteries and allow the batteries to rest 24 hours before performing this procedure to allow the battery cells to equalize 1 Open the side covers 2 Besure that the battery cable connections are free of corrosion Note Adding terminal protectors and a corrosion preventative sealant will help eliminate corrosion on the battery terminals and cables Checklist B Procedures 3 Besure that the battery retainers and cable connections are tight 4 Besure that battery separator wire connections are tight if equipped 5 Puton protective clothing and eye wear Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer Note the results 7 Check the ambient air temperature and a
197. tart line Begin timing when your reference point on the machine crosses the start line Continue at full speed and note the time when the machine reference point crosses the finish line Refer to Specifications Performance Specifications Part No 139378 September 2015 B 11 Test the Alarm Package if equipped Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first The alarm package includes e Travel alarm e Descent alarm e Flashing beacon Alarms and a beacon are installed to alert operators and ground personnel of machine proximity and motion The alarm package is installed on the turntable covers 1 Atthe ground controls pull out the red Emergency Stop button to the on position and turn the key switch to ground control Result The flashing beacon should be on and flashing 2 Move the primary boom switch to the down position hold for a moment and then release it Move the secondary boom switch to the down position hold for a moment and then release it Move the jib boom switch to the down position hold for a moment and then release it Result The descent alarm should sound when each switch is held down Checklist B Procedures 3 Turn the key switch to platform control 4 Atthe platform controls pull out the red Emergency Stop button to the on position Result The flashing beacon should be on and f
198. ting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications 1 Raise the secondary boom enough to access the primary boom lift cylinder barrel end pivot pin 2 Raise the primary boom enough to access the primary boom lift cylinder rod end pivot pin Genie BRAND Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N 63 Part No 139378 Primary Boom Components September 2015 3 Support the primary boom lift cylinder with a 9 Remove the pin retaining fastener from the suitable lifting device Place a block of wood ground control side upper secondary leveling across the upper secondary boom to support link pivot pin at the upper pivot same side of the cylinder when the rod end pin is removed machine as the primary boom lift cylinder 4 Attach an overhead crane to the primary boom at the platform for support Raise the 10 Place a rod through the upper secondary primary boom using the overhead crane just leveling link pivot pin at the upper pivot and enough to relieve the pressure on the primary twist to remove the pin Boom Niecy nner rod eng 11 Swing the leveling link up out of the way 5 Remove the counterweight cover fasteners secure it from moving dies 12
199. ual Hydraulic Component Specifications Manifold Component Specifications Specifications Function pump Plug torque Type Fixed displacement gear pump SAE No 2 36 in Ibs 4 Nm Displacement 0 183 cu in SAE No 4 10 ft lbs 13 Nm 365 SAENo 6 14 ft lbs 19 Nm Flow rate 2800 psi 172 bar 2 1 gpm SAE No 8 38 ft lbs 51 Nm 7 9 L min Hydraulic tank return filter 10 micron with 25 psi SALDO IY SITES SS AM 1 7 bar bypass SAE No 12 56 ft lbs 76 Nm Function manifold System relief valve pressure 2800 psi Z 30 20N and Z 30 20N RJ 193 bar System relief valve pressure 3200 psi Z 34 22 and Z 34 22N 221 bar Primary boom down relief pressure 1600 psi 110 bar Secondary boom down relief pressure 1600 psi 110 bar Primary boom extend relief pressure 1800 psi Models with rotating jib 124 bar Turntable rotate relief pressure 1100 psi 76 bar Auxiliary pump Type Fixed displacement gear pump Displacement 0 3 gpm 1 14 L min Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice or obligation Valve Coil Resistance Note The following coil resistance specifications are at an ambient temperature of 68 F 20 C As valve coil resistance is sensitive to changes in air temperature the coil resistance will typically increase or decrease by 4 for each 18 F 10 C that your air temperature increases or decreases from 6
200. ubject to change without notice or obligation Genie 6 Z 30 20N 2 30 20 RJ 2 34 22 gt Z 34 22N Part No 139378 September 2015 Service Manual Specifications Hydraulic Hose and Fitting Torque Specifications Your machine is equipped with Parker Seal Lok ORFS or 37 JIC fittings and hose ends Genie specifications require that fittings and hose ends be torqued to specification when they are removed and installed or when new hoses or fittings are installed Seal Lok Fittings hose end ORFS SAE Dash Size Torque 4 10 ft lbs 13 6 Nm 6 30 ft lbs 40 7 Nm 8 40 ft lbs 54 2 Nm 10 60 ft lbs 81 3 Nm 12 85 ft lbs 115 Nm 16 110 ft lbs 150 Nm 20 140 ft lbs 190 Nm 24 180 ft lbs 245 Nm JIC 37 Fittings swivel nut or hose connection SAE O ring Boss Port tube fitting installed into Aluminum all types SAE Dash Size Torque 4 14 ft lbs 19 Nm 6 23 ft lbs 31 2 Nm 8 36 ft lbs 54 2 Nm 10 62 ft lbs 84 Nm 12 84 ft lbs 114 Nm 16 125 ft Ibs 169 5 Nm 20 151 ft Ibs 204 7 Nm 24 184 ft lbs 249 5 Nm Adjustable Fitting 1 jam nut Non adjustable fitting SAE O ring Boss Port
201. ure limits OR 13 F to 185 F 25 C check for debris to 85 C OR machine around motor being driven under controller preventing excessive load OR proper cooling of the motor controller is not controller OR check for being cooled mechanical restrictions sufficiently causing excessive load on the machine 98 Genie Z 30 20N Z 30 20N RJ 2 34 22 2 34 22 Part No 139378 September 2015 Service Manual Observe and Obey Troubleshooting and repair procedures shall Schematics About This Section There are two groups of schematics in this section Electrical Schematics Electrocution burn hazard A WARNING Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry be completed by a person trained and qualified on the repair of this machine 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 V Be sure that all necessary tools and test equipment are available and ready for use V Immediately tag and remove from service a damaged or malfunctioning machine V Repair any machine damage or malfunction Hydraulic Schematics A WARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oi
202. used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Indicates a imminently hazardous situation which if not avoided will result in death or serious injury AWARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury A CAUTION Indicates a potentially hazardous gt 139378 situation which if not avoided may cause minor or moderate injury Indicates a potentially hazardous situation which if not avoided may result in property damage 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 Safety Rules Workplace 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 Genie BRAND Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N vii 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
203. ve the pin retaining fastener from the lower secondary boom compression arm to turntable riser pivot pin Use a slide hammer and remove the pin Remove the compression arm from the machine Repeat for the hydraulic tank side lower secondary boom compression arm Crushing hazard The lower secondary compression arm could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane Attach a lifting strap from an overhead crane to the lower secondary boom 61 Remove the pin retaining fastener from the lower secondary boom to turntable riser pivot pin Use a soft metal drift to remove the pin 62 Remove the lower secondary boom from the machine AWARNING Crushing hazard The lower secondary boom could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane Service Manual September 2015 Secondary Boom Components 5 2 Secondary Boom Lift Cylinder The secondary boom lift cylinder raises and lowers the secondary boom The secondary boom lift cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure How to Remove the Secondary Boom Lift Cylinder AWARNING Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and
204. wer performance The battery will need to be recharged more often Proceed to step 11 Result One or more battery cells display specific gravity from 1 217 to 1 173 The battery is approaching the end of it s life Proceed to step 11 Result The difference in specific gravity readings between cells is greater than 0 1 OR the specific gravity of one or more cells is less than 1 177 Replace the battery 11 Check the battery acid level If needed replenish with distilled water to 1 8 inch mm below the bottom of the battery fill tube Do not overfill 12 Install the vent caps and neutralize any electrolyte that may have spilled B 2 Inspect the Electrical Wiring Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining electrical wiring in good condition is essential to safe operation and good machine performance Failure to find and replace burnt chafed corroded or pinched wires could result in unsafe operating conditions and may cause component damage A WARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Remove the drive chassis cover from the non steer end of the machine 2 Inspect the following areas for burnt chafed corroded and loose wires e Electrical power panel e Electrical relay panel e Ground control pan

Service Manual - Genie Industries

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