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Service Manual - Genie Industries

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1. A B C D E F G H MANIFOLD HARNESS TO GROUND CONTROL BOX 1 5 5 3 5 de 6 _ 5 5 3 5 8 NI 18 dr EE zu Sa k gt amp 3 5 4 88 58 5 8 E BS 82 58 8 x z 2 5 x els 58 2 884 m ojo am oc amp amp 2 SERVICE HORN E z 5 5 TILT SENSOR a ui WH 5 5 8 5 zE 45 E gt lu tz Be Ra 5 ES RD 55 a 55 ES Ea 58 88 5
2. RD C32 1 p OON USE X RD WH 48A H3 TILT SENSOR nem a P 0 52 Bk 8 N BREDA 0 SWITCH PANEL O 1 RD 1348 2 BLAD 2 1 0 t Gp 049 7 222 GNK O BR C48 3 OR RD 42A WH BK 19C 48C BR 32 12 P1 TO TERMINAL BASE 3 AND CONNECTORS ONCO RD O48 1 ONCO 1 2 1551 RD AS4A L45 4 22 RD C23 8 RD 27A 145 BK 7A LABEL DESCRIPTION WHIRD GA Pi EMERGENCY STOP BUTTON NH TS63 KEY SWITCH 30 RIONLY ORC22 851 AUXILIARY TOGGLE SWITCH cM C
3. T N e 1 1 1 1 al x n E 5 5 5 8 Ala E E 1 3 5 1 8 5 8 ida g 8 E 55 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 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 BES 8 BK WH BKANH 028 12 WH 18 2 1 e 1 gt WH BK EN tees aig AX 5 122 DRIVE fr ars 3 595 1 5 1 s 89 4 i x 22 8 1 a gts 5 4 E Zs 25 4 WH RD 1 gt RA2BATOR RD C1B 9 WHIRD WH 182 BE HE 1 1 lae n 1 1
4. N Ut 19 1 i 1 i M 4 8 8 i 3 198 o 2 585 5 1 1 1 1 1 1 1 1 if 1 1 1 1 1 1 1 1 1 M 1 1 EE 5 C2P 12 16 4 DES MU 8 Yay 0 WH BK s s 5 EE 5 6 37 gt 82 ere 2 11 BR 19 4 ER sus 1 1 P46LPS WH RD C2P 10 WH 16 4 ee eK Lp pe T4 1 1 1 1 1 1 1 T 2 R42BATOR RD 4 E ORRD 5 2 BR
5. Electrical Schematic AS CE from serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 Service Manual N 5 E 5 2 qo 5 T 23 3 8 iB 5 g 9 8 a 5994 8g 3 8 8 a ul Y 8 i zx E 1 ae alg B i FS1 FOOT SWITCH E R42PWR C2B 4 IT 5 g a 8 5 a 48 5 U35 TIME DELAY 8 amp B 8 3 we 8 i BRN CR2 RELAY 48V DC POWER 5 BRN CRI RELAY E zs 1 48V DO POWER 7 FLASHING OPTION 1 DEM 2 wil 8 lt E RB 4 RD je TILT SENSOR E LIJ 3 8 GROUND BASE 29 71 l GONTROL BOX
6. TERMINAL TB DESCRIPTION CIRCUIT WIRES FROM CONNEGTOR TO CONNECTOR FLASH BEACON 134 RD Ca2 1 KEYSWITCH POWER P194BAT WIRES CIRCUIT FROM DESCRIPTION RDAWH TILT WH G7B 2 134 RD KSI 4 KEYSWITCH POWER WH cio 4 181482 JUNCTION BR CB2 BK FLASH 52 BR MH BR CR4 GROUND BATGND cud BK J2 C52 1 162454 JUNCTION 8 2 7 3 52 BR BR SP GROUND BATGND RD AWH CRS 48 RD WH MH RDAWH SP BRAKE RELEASE R48BRK M gena 8 AD ROTATE ONSE CA6JRL C2B 2 18 86 SP JIB ROTATE LEFT Z30NR ONLY OR RD CR1 628 4 42 OR RDO49 10 OR AD L3 SWITCHED 48V ek HR ane ee iB BENIN 16 sueco BL BK C1B 11 37 BL BK MH STEER RIGHT O878CW di CGU sep mm som 1 10 36 BL MH STEER LEFT ox cie a ee D CRS 27 R ns P WHIRD 6 8 6 JOYSTICK POT LOW WH 32 4 22 BK SP BK CR4 24V TO PLATFORM P22BAT m nm pem TB36 TB37 GRAWH CRS 18 GRIWEHMH LIFT PUMP CISLPE Wi 8 4 PIPER QRWH 7 19 GR WH SP LIFT PUMP
7. G H K L M RD C32 1 1 RD WH BA BR 52A O SWITCH PANEL 6 RD 1248 2 BUD 026 1 1 GN BK WHBK 19D 48C BR 32 12 ONCO TO TERMINAL BASE NG O 3 AND CONNECTORS RD C4 amp 1 1551 1 Sw ds 51 us 4 BK 22A RD C23 6 RD 27A 1 OR BK 15A BK 7A 8 WH RD 6A 4 1559 JIB ROTATE 2 8 1868 Z30NRJONLY ORC22 090 Jo I 4 4 1 R E L 2 OR 14A 5321 GN BK 18A GN WH 19A 1957 BLWH 01 12 D 9 ODO BK22C 4 1558 c LAR 4 Qu p g g 2 WH BK 5A TS62 WH 4A DER d aon Hac em 690 6 5 1555 QQ Q7 CN LASS BL BK 11A RD C32 7 1 1 6 BL 10A 1 8 4 5 6 7 8 12 7 C32 A ES34DCU 033 8 Genie Part No 139378 Z 30 20N Z 30 20N RJ 2 34 22 2 34 22 153 Service Manual January 2015 _____ _______________ _ _ _ __ ___ Ground Co
8. 151 EXTEND RETRACT LIMIT SWITCH SHOWN WITH BOOM EXTENDED c10 BK 7 13 14 WH 7 pine WIRES 21 22 1 BK CABLE 7 2 WH 152 PRIMARY BOOM LIMIT SWITCH ci PIN WIRES 1 RD 2 BR 3 BK 4 WH DRIVE ENABLE LIMIT SWITCH WIRES SHOWN WITH BOOM ROTATED PAST EITHER NON STEER WHEEL 1 RD BK 5 13 14 RD 5 2 BR WH 5 21 22 BR 5 8 BK CABLES 4 WH 154 SECONDARY BOOM LIMIT SWITCH C52 13 14 WIRES WH 8 21 22 BK 8 1 BK CABLE 8 2 WH NOTE ALL LIMIT SWITCHES SHOWN WITH THE BOOM IN THE STOWED POSITION EXCEPT WHERE NOTED January 2015 Service Manual LVI BCI Option Wiring Diagram A B D E H K L M 1 Ou Tats 2 C7B O O TS7 SENDEN 2 2 5 58 8 3 5 o 3 C47 JIB TS13 TS10 ONC O P2 O NC C2P 4 4 7 8 P 22
9. 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 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 RDL3 SWITCHED 48V 42 FE 1 11 37 BL BK MH STEER RIGHT C378CW sci BLCiB 19 98 BL MH STEER LEFT 635566 RD CRS 1 27 RD SP AUXILIARY PUMP C27AUX 10 2 23 4 22 BK SP BK CR4 424V PLATFORM 22 TB36 TB37 GR WH CR3 18 GRAWH MH LIFT PUMP 16 eoe GRMH C4B 7 19 GRAVH SP LIFT PUMP C amp 1 OR RD C4B 4 16 OR RD CR5 DRIVE ENABLE CieDE OR BK 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 T 5 SECONDARY ROOM DOWN C11SBD BLC3B 10 10 BL MH BL SP SECONDARY C10SBU BKWH C3B 8 8 BKWH MH PRIMARY BOOM RETRACT C8PBR BK C3B 7 7 BKMH BK SP PRIMARY EXTEND WHIRD C3B 6 6 WHRD MH WHIRD SP FUNCTION
10. INHOA V 1d NOTES 4 gt TURNTABLE TILT ALARM LED OPTION IW ON 2 34 22 MODELS THIS LOCATION IS USED FOR 1549 WORK LIGHT OPTION 0 bud Be 1 15 09 rs 0 69 uc bo 077 066 TS9 7512 7 Q P3 z OQO H O O 039 LO 0 OM O4 LO J 4 C47 JB TS11 8 00 2 o LO NC O4 280 PO NCQ 1913 TS10 cop 5 or 2 g A cap 5 E 7919 e 158 gt vr 071 Ix o zum 884 8 8 8 D73 BP1 2 a 3 5 1 Z T 5 148 z x Eo EE g 1540 5 4 E _ DPI WH RD 849 8 2 4 4 5 8 7 L L4 LABEL DESCRIPTION P2 EMERGENCY STOP BUTTON HORN BUTTON DPI DRIVE CONTROLLER BP1 BOOM FUNCTION SPEED CONTROLLER AUXILIARY TOGGLE SWITCH PLATFORM ROTATE TOGGLE BWITCH __ JIBBOOM UP DOWN TOGGLE SWITCH PLATFORM LEVEL TOGGLE SWITCH SECONDARY BOOM UP DOWN TOGGLE SWITCH gt p g glo glo es 3 o e ges __ PRIMARY BOON UP DOW
11. NOTES 1 EOM ul 1 gt gt TURNTABLE ALARM LED OPTION ON Z 34 22 MODELS THIS LOCATION IS USED FOR WORK LIGHT OPTION 7649 ue Ea 1 OJ 0835 Y T515 5 5 TE 2 TS1 l nr 1 077 4 _ 12 TS7 4 poo n 040 8 D Y 8 No 0 5 ie KORS LO 1 j C47 3 JIB E gt lt TS11 CAP P2 ERR Dau EE 2 5 TS1 und PO e m g E S 5 7 85 8 2 2 p 8 on DAU 9 LO d H 8 8 4 BCI D71 T OPTION gt 8 8 J T 8 Lo 5 8 5 P 5 5 5 9 073 T 8 E 6 5 ie AD BK 9 Deb 3 _WHIRD TS49 5 1548 or RD DPI E LABEL DESCRIPTION CR45 RELAY WORK LIGHTS OPTION
12. TIFE 5 Cae Ne Ne Ex a8 28 N lt N 139378 Genie Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N 118 Service Manual January 2015 Electrical Schematic ANSI CSA AS before serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 C29 8H RD WH C29JSH RD WH 032081 WH RD 32081 WH RD N LO 5 BRN BATGND BRN 1 8 C13DEL BLAD C4B 1 Ci3DELBL RD 4 WHS A BARNS Fl 1 i 81 n 12 C12FTSBLWH 638 12 C12FTS BLWH BKS PEL E C16DE ORPD tH we 4 88 8 FASBRK PEG oe 4 4 4 8 58 5 E 8 en 1 a C1P 10 096900 BL 0 BL Ga 4
13. 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 the Drive 26 B 9 Test the Drive Speed Stowed 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 30 B 13 Check the Electrical Contactors 30 B 14 Perform Hydraulic Oil 31 B 15 Test the Emergency Power System 31 Gonio BRAND Part No 139378 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N ix January 2015 Table of Contents Checklist C 33 C 1 Grease the Platform Overload Mechanism if equipped 33 6 2 Test the Platform Overload System if 33 Checklist D
14. 91 Non steer Axle tnnnne nnn nnn nnt 93 10 1 Motor Controller 2 420022 00 000 93 Genie BRAND Part No 139378 Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N xi January 2015 C M n Table of Contents Section 5 Section 6 xii Fault 94 94 5 99 99 Electrical Symbol Legend ttr Dr 100 Hydraulic Symbols 101 Limit Switch Location 102 Electrical 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 Option 112 Option CE Models ei ete ce Eee t re d 113 Hydraulic eene 115 Hydraulic rera DR ERROR 116 Genie RJ 2 34 22
15. 1 1 1 T 7 1 AD BK 2A H H T i T H 1 ES34DCU Genie ATEREX BRAND Part No 139378 Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N 143 Service Manual January 2015 Ground Control Box Switch Panel Wiring Diagram ANSI CSA from serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 144 145 January 2015 Service Manual _ Platform Control Wiring Diagram ANSI CSA from serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 January 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 834000 P48LPS WH C2P 10 WH RD 7548 RELAY N O WORK LIGHTS EMERGENCY STOP BUTTON FUNCTION SPEED CONTROLLER PLATFORM ROTATE TOGGLE SWITCH PLATFORM LEVEL TOGGLE SWITCH SECONDARY BOOMUP DOWN TOGGLE SWITCH TURNTABLE ROTATE TOGGLE SWITGH EXTEND RETRAGT TOGGLE SWITCH DRIVE ENABLE TOGGLE SWITCH JB ROTATE TOGGLE SWITGH 290 ONLY BATTERY CHARGE INDICATOR OPTION TURNTABLE TILT ALARM LED 5 OPTION HORN BUTTON DRIVE CONTROLLER ee LABEL
16. CaP 8 RD WH coa EM yi MM N ud ADAH d n L e WE 2 n C2BTTARDEK 2 RD BK WH a C7P 2 23 WH 8 f AD 1 4 BK BRN 4 lt B 8 Be z 3 MET gl RD V COHRNBKRD g Y 8 49 1 RZZAUX x DET DL EC 552704 Y YN P22BATBK 22 G7B 1 049 11 __ 8 8 4 55 5 8 8 5 5 RABAT 3 gt 2 lt T amp 5 EE BK RD 8 3 BRN s 5 a 5 AD g 227 5 10 1 BK 7 3 a m PazBAT g 55 5 508 M 3 8 E 61 4 WHE mye on 52 2 WHS CHa BKS R 8 mee 3 ag 5 Qm X C49 T CITRCSLBK T 2 49 2 C4ABAK RDEK 20 4 et CHa2PWR onm case OR OFFLIMTSPDINP 58 4 uj EG 005 wrROKS 8 CIPS C29J8H HD WH 3 E RD WH 46 33 gx E CIP 6 Ca2J8L WHAD 46 WH RD 5 8 1 E CIPS gt
17. Ground Control Box Switch Panel Wiring Diagram before serial numbers Z30N10 12119 Z34N10 8857 and 23410 7774 134 135 January 2015 Service Manual Platform Control Box Wiring Diagram CE before serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 r Platform Control Box Wiring Diagram CE before serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 A B C D E 9 22 Qu udrzro 9270 fero 136 279 NEVO 5 79 HM January 2015 1270 HO 2147 HHdZ LS Genie ATEREX BRAND Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N Part No 139378
18. 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 and 23410 7774 156 Genie xiv Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N Part No 139378 2015 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 22 7 17 5 199 nut torque dry E 56 18 44 PIE Load range 7600 Ibs Lug nut torque lubricated 3447 kg Overall tire diameter 22 Fuel capacities 56 cm 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 cm Drive hubs 48 1 24 5 fl oz 0 72 liters Tires and Wheels eme 57 1 24 5 fl oz 0 72 liters Tuscus Drive hub oil type SAE 90 multipurpose hypoid gear oil Tire ply rating 12 service classification GL5 Tire weight new foam filled 175 Ibs minimum 79 kg tire diameter 28 in For operational specifications refer to the 71cm Operator s Manual Wheel diameter 14 5in Continuous improvement of our products is 290 policy Product specificati
19. ME 1 1 1 tee 4 1 1 NE 2 4 Ra2BATOR RD CA4 T onn 1 43 3 275 8 5 88 EM 1 3 C3BATRDAMH 3 BRN 48V POWER 8 RELAY 2 BRN POWER 5 8 RELAY 1 EY QU T qo Y 1 FLASHING BEAGON 5 ag i a TT 4 QQCNUTARDEK RD BK WH V 2 0 2 RD BKS BAN BENBOR 8 8 5 78 pod L 5 lt d m 1 n 1 M 3 1 1 8 1 8 8 BASE CONTROL Wd z d BOX GROUND E E 0 xe a e 41 1 23 BK RD 5 1 T 1 S a i 5 LE LIARY LIFT g 5 f C49 1 R27AUX AD PRA 2 1 n 0284 1 5 5 8 8 PRICE Y P29BATBK 8 046 1 CISLPEGAWH 8 8 PRIMARY LIFT PUMP CONTACTOR RELAY B5 1 1 a T RISLPE GR WH 1 PRIMARY LIFT DA 8i 5 a 5 PUMP E d ooo o 1 5119 C HAN BK RD 8 HORN 5 i M RELAY Li
20. BRAND Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N 73 57 Attach a lifting strap from an overhead crane 59 A WARNING 60 to the ground control side lower secondary boom compression arm Remove 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 A WARNING 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 January 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 AWARNI
21. 1 2 0 i 1 1 M caps CAWRRRD a bd PLATFORM ROTATE RIGHT JIBBOOM UP 1j z PLATFORM ROTATE LEFT d 28 8 DOWN JIBBOOM DOWN 43 1 2g ur CPS TAIJU GR C2B4 5 SS CAND GREK cope sipown 5 Ela E 1 cai WH Gt s 5 NT El i Caz n 45 15 1 B LEFT r5 P 5 CISPRA BL 15 E Ek S M g qeu 3 28 ee 0886 0486 T I T 4 UP A PLATFORM LEVEL 1 UPCOIL o ORK Pil 4 PLATFORM LEVEL Ei i vow DOWN COIL MI 4 9 1 1 Li 2 ur cape C14PLU OR 5 ri caps CIBPLDORBK 0489 1 8 11 56 I 4 BOOM EXTEND i ry 3 BKWH 4 BOOM RETRACT B RETRACT 8 E 1 1 i8 Eg EXTEND 0877
22. 5 6 La PLATFORM OVERLOAD LED 4 IB RO TATE ORION 148 TURNTABLE TILT ALARM LED OPTION Z30N RJ ONLY 2308 RJ MODELS U35 TIME DELAY RELAY 2 SECONDS 30A R20 RESISTOR 4 7k Q Genie ATEREX BRAND 156 Z 30 20N Z 30 20N RJ 2 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 Australia 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 65 67533544 Genie Japan Phone 81 3 6436 2020 81 3 5445 1 Genie Korea Phone 82 2 558 7 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 431 183 581 566
23. ess 0348 2 2 UP E RD PRIMARY gt 1 BOOM UP 33 zit E ui PRIMARY Down 8 BOOM DOWN SB 8 __ RD T OPBDRDBK m E UP a BL A 1 SECONDARY MEE 3 85 1 m BLEK i 4 SECONDARY E E 2 lie CAM 5 BY iS 4 DESOENT 9 up 3240 010980 BL 08810 BE ALARM te CHSBDBUBK DOWN RIGHT 8 eit TURNTABLE 1 ROTATE RIGHT ie m WH n 4 TURNTABLE 4 LEFT ROTATE LEFT CSTARWHBK 0885 2 M 1 34 CATRLWH copa 8 5 z 2 c LT REB az ii EHE 8 E Bl 4 P z 8 LE 8 8 8 Service Manual January 2015 ___ __________________ _ _ ____ Electrical Schematic CE before serial numbers Z30N10 12119 Z34N10 8857 and 23410 7774 130 131 January 2015 Service Manual Ground Control Box Terminal Strip Wiring Diagram before serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 Service Manual Ground Control Box Terminal Strip Wiring Diagram CE before serial numbers Z3
24. 5 H 5 8 p C2P 5 GA 25 5 GR 1 2 6 CA4JD GRIBK 028 6 GF BK 1 cel 47 4 0440 WH JIB BOOM 1 DOWN 1 BK 11 RIGHT JIB BOOM 5 i CATACITPRLOR 14 E bier PLATFORM Fs ag ROTATELEFT 47 2 BL HANS PLATFORM 6 E hcm ROTATE RIGHT B BRIGHT 4 6 OIBPRROR BK 4 CAP 5 CAZPRL GR is y a on ME Eaton LeveL 1 bi 1 o 1 Lh g rj OR BK PLATFORM LEVEL z 3 DOWN a DOWN 5 EBEN l 4 ER sia rive i O4P3 ORIBK 0488 DOWN 8 EXTEND BK n BOOM EXTEND gs 56 y e T 254 REACT g BOOM RETRACT gt 1 E 222 5 1 7 C7PBE 2 C9P 8 8 z 1 UP RD A PRIMARY esl BOOM UP 4 RD BK PRIMARY ERE DOWN BOOM DOWN 1 nm 18i 1 4 UP 191 C3P 1 CIPBU RD cagi 1 gt capo E z BL i SECONDARY a 1 2 re BLIBK n amp SECONDARY 8 B Ag DOWN 9 3
25. N 8 3 8 a 82 5 ip E 3 5 x 5 5 8 2 ORRD CZTAUX RD ag si 5 5 5 MEN 7 EIS 5 mn 8 2 zi Be 8 E x 25 8 COMFV WHIRD 8 5 eje 4 845 8 o r 5 5 WH B E iT 8 ee eee iy de 1 2 RIGHT 11 E bg 1 81 1 ab AE LET 5 5 a 52 M 3 58 OR BK 2 4 ER 1 3 HT 11 1 t B 1 1 Io ict t 8 m up C4s UGR 4 mm s OMUDGRIBK s N IEEE Fog z CAD WH HA 43JU BK id we NN 5 Ci7PRLOR A 412 Re 8 CAPD C18PAR BL LM 5 CLE 4 kE cpa CISPRRGREK C4B4 4 GITPRLGR x E 1 5 pE 28 IN n z
26. 35 D 1 Check the Boom Wear 35 D 2 Check the Free wheel Configuration sse 36 D 3 Check the Turntable Rotation Bearing 37 0 4 Replace the Drive Hub Oil 38 0 5 Replace the Hydraulic Tank Return Filter 38 D 6 Inspect for Turntable Bearing 39 Checklist E 5 0 41 E 1 Test or Replace the Hydraulic 41 E 2 Grease the Steer Axle Wheel Bearings 43 Section 4 Repair 06005 45 45 Platform Controls 47 1 1 Controllers la eed t en 47 Platform Components oe IE CX EAR ERR ERE EE 49 2 1 Platform Leveling Slave 49 2 2 Platform 50 2 3 Platform Overload 51 Jib Boom 6 5 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 Lift Gylinder
27. PUE rap ASAP UR uer ey cane me aa T Ez 1 5 g 8 5 o 3 C49 1 R27AUX RD PRS AUXILIARY 9 0284 5 E 2 LIFT PUMP S E CR 20 RELAY 5 49 11 1 1 8 7 8 8 B RI8LPE GR WH PR PRIMARY EN i BNE LIFT PUMP COIL 1 12 g 6 o 95 x 3T EL 5 I 8 a C9HRN BK RD 8 7 8 BRN RELAY JY 3 Ue HORN 2 V lt il BNE EE HORN als 5 m 8d 25 ez 8 3 E J2BK 2 JS ad 5 3 C 5 P E 8 6524 8 6 5 5 8 Cs22WHs 3 152 PRIMARY LIMIT SWITCH 4 8 1 34 SECONDARY LIMIT SWITCH gt 5 Ve 0178031 J y a BK2GA GROUND CHASSIS 8 49 2 RD BK gt CRS RELAY Se 9 BRAKE RELEASE 3 CI7ODPR PR1 MAIN PUMP 5 m E CONTACTOR u BTE a 2 55 Eu BLANH INTERLOCK y 55 3 x 33 gt 6 nex 5 5 P C1B 5 REVERSE _ C1B 4 FORWARD 3 x 3 8 n 1 DIODE RETURN 2 5 8 2 Loss eur Ee 2 5 B 5 E 5 5 8 5 E 5 4 2 gz BK BATTERY 2 E 8 a CHARGER ag 4 8 ads zg 58 E 9 8 3 aaa x FE
28. E E JN 55 ai ue CMPLUOR 1 caps CISPLDORBK 0488 TT T 1 m d 1 EXTEND BK 5 E I iip 17 A Ea TE B E it 5 5 bg 28 EXTEND iT te 28 B DOWN 8 a 1 5 ILE d C1PBU RD st ONBDRDEK zi t a 2 a rei EM vds 85 uP Lele 04810 1 3 7 T T te emn 8 f nl 5 WH A T 3 28 5 CSTAR 0385 O4TRLWH LEFT 5 Bu a x 38 9 21 EE 3B ves 5 a PERR 8 88 8888 5 1 T N e 139 DRIVE ENABLE LIMIT SWITCH TRAVEL ALARM BRAKE RELEASE VALVE BRAKE RELEASE VALVE BRAKE PRESSURE SWITCH STEER LEFT STEER FIGHT HOUR METER gt Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N AUXILIARY PUMP PROPORTIONAL CONTROL VALVE Part No 139378 JIB BOOM UP
29. 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 1 32 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N Part No 139378 January 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 operation 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 maxi
30. 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 Turn the key switch to ground controls and pull out the red Emergency Stop button to the on position at both the ground and platform controls 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 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 Colli
31. n J P2 EMERGENCY STOP BUTTON 10 1 2 3 4 5 8 7 8 9 HORN BUTTON GR BK DP1 DRIVE CONTROLLER 6 BP1 BOOM FUNCTION SPEED CONTROLLER 1 AUXILIARY TOGGLE SWITCH PLATFORM ROTATE TOGGLE SWITCH 157 JIB BOOM UP DOWN TOGGLE SWITCH PLATFORM LEVEL TOGGLE SWITCH SECONDARY UP DOWN TOGGLE SWITCH 1510 PRIMARY BOOM UP DOWN TOGGLE SWITCH 1511 lo o lo b b lo lo s x a le el o o 1812 TURNTABLE ROTATE TOGGLE SWITCH 9g 9 9 9 9 sere oo 8 9 8 m 5 E 8 8 5 8 f 9 3 3 8 5 8 8 ae 8 8 5 8 7513 EXTEND RETRACT TOGGLE SWITCH 1B Flag P 5 5 SH Bele 05906 s 5 81 8 8 52m 5 15 DRIVE ENABLE TOGGLE SWITCH 7 S m E jo E 5 D 21 8 6 og 85 gt mw A gig gig 9 8 I t m m 1516 JIB ROTATE TOGGLE SWITCH Z30NRJ ONLY 8 342 B 8 p 95 See 8 395 gt ig SIS 5 g 8 8 6 3 886 0 og Ble 2 8 8 25859225 g 5 2 p 2 9 o 5 4 m 5 815 3 8 TILT ALARM E 3 2a 55 g 5 g BATTERY CHARGE INDICATOR OPTION 2 E B g 5 ef 3 R IS 5 oA A uH T DRIVE ENABLE LED
32. wii ET um ORRD OR RD C4B 4 16 OR RD CRS DRIVE ENABLE EE Costi mm mE OR BK C4B 3 15 OR BK MH OR BK SP PLATFORM LEVEL DOWN hk 5 mn PLXTEGBM ROTATE RIGHT OR C4B 2 14 8 PLATFORM LEVEL cies 18457 8 PLATFORM ROTATE LEFT BLAN 12 BK nea 8 FOOTSWTEH BLRD 4 CAB DRIVE ENABLE LIGHT BL BK 11 1 BUBK MH BL BK GP SECONDARY BOOM DOWN Garni fags URS HGEN 10 BLSP SEGONDARY BOOM UP C3B 3 m 486 CR2 486 4BV RELAY COIL POWER 8 8 BKWH MH BKIWH SP PRIMARY BOOM 8 CARO peu ER TO GN POWER BK C38 7 7 BkMH 8 PRIMARY BOOM EXTEND 7 GARAE porem BRAKE RELEASE WH AD C3E 6 6 WHRD MH WH RD SP FUNCTION SPEED CONTROL WH BK C3B 5 5 WHBK MH WHIBK SP TURNTABLE ROTATE RIGHT C5TRR WH 638 4 4 WHMH WHP 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 UP 1 0 C2B 12 WH RD 27D 128 TERMINAL BASE 3 GR WH 19C WH AND RELAY BLOCK OR RD C48 2 49 11 BK 22A GND BR CRI CR 1 4 H BR 52A CR23 RD WH C3B 3 uw AP2 448VDC pig RD LT BK RD MH HORN DRIVE LIGHTS OPTION OR RD 42D BK
33. 2 Open the platform control box lid and locate the boom function speed controller black red wire diode white red wire boom function speed controller ramp rate trimpot threshold trimpot max out trimpot NOOR WD Genie BRAND Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N 47 Part No 139378 Ss 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
34. FASBHKHDWH tr BRAKE RELEASE NO g BRAKE RELEASE NC repr FEI 4 BRAKE RELEASE E PRESSURE SWITCH wi 010 1003890 BL 0 BL n 4 STEERIEFT CTP TI C978CC BLEK 1 11 BLEK n 4 STEER RIGHT P z x 1 5 1 i 9 1 1 1 1 15 BL 88 8 gx Hl 5 BIS 5 ee Ge HOUR METER B pp C2TAUXRD 4 C1B 1 WH AUX gt 8 H 5 a 55 a 4 lt gs 218 83 de y 98 4 AUXILIARY CONTROL OR RD zh RELAY 85 a E 2 ire wo E meal e BR z 8 5 p 94875 C4B 7GRWH j Ci9LPE GR WH g 51 C3P 6 WHRD 6 WHRD PROPORTIONAL elI x CONTROL VALVE ac Oo 5 5 5 amp 6 WH y 5 8 5 l 8 e e LEFT g E 3 r l se 2 91 E s pa 8 RIGHT CaP 8 C47JRR OREK C28 3 OF BK 55 B 02 2 CAGJRL OR C2B 2 OR i 1 H 5 JIBBOOM k ROTATE LEFT iL caze 4 JIB BOOM ae ROTATE RIGHT DOWN cl ag is
35. WHIBK GIRS C495 WHK REVERSE 4 3 019 4 CSOFWD WH C1B4 WH FORWARD i Q DIODE RETURN 9 RAT ORD ly 48V INPUT 1 E 5 5 8 5 5 t WH 4 4 lt eqe 4 E 9 6 oe 2 5 8 SSS ego P182BAT RD RD20 z 5 SS 1 1 z NJ ENJ JEN EN EN 4 55 N ES34DCU L29 DRIVE 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 GONTACTOR 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 8HOWN 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 E SETUP ENABLE USE TO SET THE BATTERY INDICATOR PROFILES Genie Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N Part No 139378 138 Service Manual January 2015 El
36. 3 8 GR WH PRIMARY a 1 2 a 5 COHAN BK AD BRN HORN o RELAY ME T BK HORN 3 P22L8 BK 0 af 4 5 gts LS1 EXT RET Es 1 J2BK 002047 7 hal 4 5 3 52 1 8 cna wies i 5 052 2 WH 8 61 3 LB2 PRI UP DWN 3 8 154 550 UP DWN 5 1 ag Bg 3 ag 5 i CHASSIS GROUND a AY 49 2 CABRK RD BK 29 BRAKE RELEASE 8 9 RELAY X Pm CIBZPWH GRN PRI DRIVE 588 i iE 5 C490 OR OFFLIMTSPDINP 4 8 55 d id ieu ul 1 INTERLOCK 2 E RD WH 16 84 Sz 1 6 POT LOW 5 C495 WHBK REVERSE q 4 WH FORWARD 5 4 DIODE RETURN 9 k 2 a PARTIE 48V INPUT 8 5 8 is g 8 gg E od 5 5 8 5 3 E 9 E 5 8 5 i 8 zee 5 mi idm D 5 a a B 5 5 50 55 2 48 8 pee O a 8 5 2 PRIMARY uibs UFT PUMP E lt E pum 2 ie 4 AUXILIARY 8 5 2 LIFT PUMP SEES 5 5 8 3 045 Pis2bAT AD 8020 5 5 2 d ig 11
37. BRAKE RELEASE Ev NO COIL 1 4 0 BRAKE RELEASE rer PRESSURE SWITCH z 0 80 BL ael 1 STEERLEFT SI F 4 09780 186 CIB H BLEK A 4 STEER RIGHT e 1 a NI 8 N 2 3 1 9 rS EIE e 44 P 8 Mi 8 v 1 ig 9 aj HBK METER 1 gt i GRAUXRD 41 RD AUX OQ 1 5 8 t T 5 a 5 gt x x i ai 8 8 5 N t 832 m B caer 82 AUXILIARY CONTROL ORD ve 4g 4 RELAY z 5 ale tjo gt 8 eo 2 CAP 7 gt C19LPE 7 C4B 7 N 55 88 8 x 55 8 WHAD C3B 8 WHIRD eje 4 PROPORTIONAL CONTROL VALVE 8 2 2 8 UNS WH 5095 nt te EMIL RIGHT bi pet te LEFT ow ES s e 4 58 EL HT 59 Ls 2 3 C47JRR OF BK FI 5 Em
38. January 2015 Service Manual 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 coil defective OR contactor PR1 or brake release relay brake release relay CR5 defective CR5 OR replace the motor controller 32 MAIN CONT WELDED Machine will not drive 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
39. Part No 139378 Service Manual January 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 lbs Platform rotator 31 1 2 13 bolts GR 5 lubricated 57 ft Ibs Jib boom rotator 77 Nm Platform rotator 2 30 20 Z 34 22 and Z 34 22N 3 4 10 bolt GR 8 lubricated 280 ft Ibs 379 Nm 3 8 16 bolts GR 8 lubricated 23 ft Ibs 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 subject to change without notice or obligation Genie 6 Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N Part No 139378 January 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
40. 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 can penetrate and 13 Open the platform control box PUR ih Loosen De 14 disconnect each wire from the cables Cee elie aly 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 pa ihe boom at the pivot then remove the cable track from the boom Sue ee WINNI 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 BIS OF pinched Hoses can be damaged i
41. iiie easet 58 Genie X Z 30 20N Z 30 20N RJ 2 34 22 2 34 22 Part No 139378 January 2015 AD J d Table of Contents Primary 5 59 4 1 Cable Track 59 4 2 BOOM 60 4 3 Primary Boom Lift Cylinder 63 4 4 Primary Boom Extension 2 nmn 65 4 5 Platform Leveling Master Cylinder 67 Secondary Boom 68 5 1 Secondary BOOM tete tii le ie echa 69 5 2 Secondary Boom Lift 74 Hydraulic eene enne nnne nnne tnnt natn nnn 77 6 1 Auxiliary and Function 77 Ma NOS 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 a 87 Turntable Rotation Components nenna 90 8 1 Turntable Rotation Hydraulic 90 Steer Axle 4 444 4 0 10 91 9 1 Hub and
42. 12 2 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 y N Motor Gy J 8 teuit Teakor y Datus N 10 ight Genie BRAND Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N 95 Part No 139378 January 2015 Fault Codes Fault Code Chart Fau
43. A TEREX BRAND enie Serial Number Ran ge Z 30 20N Z 30 20N RJ Z 34 22N Z 34 22DC from 730 08 11500 Part No 139378 Rev B2 January 2015 January 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 improvement All communications will be
44. DESCRIPTION P2 DPI TSi 157 1510 TS 7812 1818 1815 1516 H1 148 C7B 2 132 BL WH C1P 12 C28TTA RD BK 2 P23BAT WH C7P 2 C12FTS BL WH C3P 12 C16DRE OR RD 4 4 5 WH BK 5 CATRL WH 4 ON Z 34 22 MODELS THIS LOCATION IS USED FOR E gt T849 WORK LIGHT OPTION CISBD C3P 11 gt TURNTABLE TILT ALARM LED OPTION NOTES C10SBU BL C3P 10 CeMFV WH RD 6 WH RD CR45 86 9 som P26BAT RD 2 B m 3680 C18PRR GRIBK C4P 6 C17PRL GR 5 WORK LIGHTS OPTION bol D77 TS12 RO LO 9 1510 071 8 BP1 RD BK TS11 C43JU GR C2P 5 G19LPE GR WH C4P 7 073 C44JD GR BK C2P 6 C2PBD RD BK C3P 2 C1PBU RD C3P 1 4 4 4 C14PLU OR C4P 2 47 C2P 3 C
45. 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 C v Y 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 0 9 11 12 Genie Z 30 20N Z 30 20N RJ 2 34 22 2 34 22 January 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
46. 5 BB 8 3 gt ING 5 i is T N e AO N Genie Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N Part No 139378 128 Service Manual Electrical Schematic CE C28J5H 08251 WH RD C31REV WH BK C30FWD WH P24BAT WH before serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 January 2015 P24BAT WH C29J5H RD WH GS2JSLWH RD C81 REV WH BK C30FWD WH N e 3 BATGND BATGND a a at y Y CISDELBUHD 0484 CiSDELBLRD 4 45 A BANS Ce Fl T di gt al DRIVE ENABLE T al 12 _C12FTS BLWH 12 a CIZFTS cas 5 5 LIMIT fa gri CI DEORRD 1 e we o u RD WH 4 TRAVEL ALARM Jud PER 1 g 5 m BRAKE RELEASE lt ZI tt NC COIL 1
47. ANSI CSA AS Service Manual I 1 1 129 DRIVE LIGHT OPTION 1 PABLPS WHIRD 140 WORK LIGHTS Es OPTION 1 1 1 1 1 1 1 1 1 d 1 t I 1 1 1 1 1 1 1 1 1 1 1 1 1 T 1 1 I 1 1 2 4 0 1 5 5 8 48V POWER 3 sa RELAY CR2 8 BEN 48 POWER y 8 8 RELAY ay gt NICE _ROAWH Yay FLASHING A 1 i OPTION E Ke AOL Ed 4 2 RD SK WH 8 cma gl RD AD e BK TILT SENSOR 5 8 a a ios BI 86 1 BASE CONTROL m 8 BOX GROUND goth 29 2 BD 2 1 Ey 2 8 M S Ei 49 1 RZ7AUX g PUMP copi y CIBSPLADURD Al ME amp 1 1 CILPEGAWH 8 1 8 PRIMARY LIFT PUMP 1 oe RELAY i is a
48. B s HORN E PZ2LS BK C101 7 2 LSTEXT RET 1 5 6192 WH 4 lt SCR 5 52 1 BK 8 i Cit 4 WHE OR 052 2 WH 8 46 LSz PRI UP DWN 1 wy 3 L84 SEC UP DWN 1 5 ex 38 048 7 0178081 BK 5 V CHASSIS GROUND accede cc qORAD 049 2 BRAKE RELEASE 8 RELAY ORS PRI C182PWR GAN DRIVE a E 8 88 deg 9 9 0499 On OFFUMTSPDINPS g 55 1 d e m 8 C29J8H 3 ADH HI 16 Sx 8 5 WHRD 049 6 WHAD POT LOWS 14 5 8 1 CIPS CSTREV WHIBK 0185 5 WH BK REVERSE 8 1 4 WH 0184 4 WH FORWARD 3 d DIODE RETURN 9 2 d 48V 5 Zg 5 EE i 5 g EL 5 19 8 2 a 2 5 8 5 9 4 mg BK i mz i fk 2 u 8 208 22 2 ra 7 i S a lt PRIMARY 82 54 gt fiiis 5 5 gt ES gre aa 8 5 Ee 2 AUXILIARY 8 go 5 LIFT PUMP gz 5 gt 028 os gt C46 1 RD RD 20 8 8 5 aiii ge E par Ec ET 5 5 49 ij N lt
49. CIP 06780 BLEK In a 5 2 8 iT ehh T al 8 5 5 5 WHIBK aem a r READ e pL CIE 1 8 1 a g Pag i Zz s i 5 6 KES E 8 7 258 DNE ORRD BRR 7 RD C491 gt 5 5 4422 11 3 z 8 4 8 z gt 7 GIGLPE 4 7 88 GIBLPE 8 zal Lal a 58 4 C8P 6 COMFV WH RD Set 5 WHAD 4 E 1 gt 5 Eaae i hs 83 SE pay tse ae ay 1 1 RIGHT 1 8 55 AB FE ien ERE i 3 el 55 us 1 2f CAZJRR ORK nS Tc S51 0P2 C4 amp JRL OR 025 2 i 1 4 4 1 Les 4 B bd C2P b C47JRR RD 4 uP gt 79 ee oe Ege 1 DOWN 58 4 111 C255 6 C44JD GREK C474 CAMDWH 040086 1 I
50. DRIVE CONTROLLER BOOM 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 CR 3 BPI T 10 Tsi2 5 Hi 1320 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 BL BK 11 C10SBU BL C3P 10 TS10 C6MFV WH RD CSP 6 4 D71 BP1 BK RD RD WH RD CR45 486 RD BK P26BAT RD P2 ES34DCT C18PRR GR BK 6 C17PRL GR C4P 5 C43JU 2 5 C19LPE GR WH 7 073 C44JD 2 6 C2PBD RD BK 2 C1PBU RD C3P 1 C14PLU OR 2 OR BK 2
51. Ex i So 55 fia 25 ao ao gt aw 3 3 BE ak Glee SG Sele eels See 1 p 1 Q Q Q E h l BRAKE PRESSURE SWITCH E MF m 7 gme 2 qE SQ 53 Se as Sole cw cw Q 4 1 1 I I 1 I I 1 I I 1 I I 1 ELS 9 9 BRAKE RELEASE N C VALVE 6 6 990 o ET 2 2 5 9 2 B BRAKE RELEASE N O VALVE JIB MANIFOLD WITH JIB ROTATE OPTION Z30N RJ ONLY JIB PLATFORM ROTATE MANIFOLD TOP VIEW JIB GABLE TO PLATFORM BOX TOP VIEW JIB CABLE TO PLATFORM BOX o C47 6 CU EN pem RD JIB 2 7 BL JIB PLAT R E UP E is E WIB UP es 1 CJ PIN WIRES ROTATE WIRES CIRCUITE WH JIB S YL JIB 1 JOR C17PRL i wae 1 OR CI7PRL 5 ORNIB JIB DOWN 2 BL C18PRR 2 BL 7 E e 8 BK C43JU ROTATE LEFT POMA 3 BK har 4 C44JD 4 5 YL pik aur 6 RD C47JRR EET BR JIB 7 ES34DCU GROUND Te 8 2 8 GND 2 8 BR GND Genie 108 ATEREX BRAND Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N Part No 139378
52. Oo O O 5 O O D E TILT SENSOR m wa 22 _ Bk 9 _ L3 BR 52D T T BK C49 7 BR C48 3 OR RD 42A LABEL DESCRIPTION P1 EMERGENCY STOP BUTTON KEY SWITCH 1651 AUXILIARY TOGGLE SWITCH 855 FUNCTION ENABLE TOGGLE SWITCH 1557 PLATFORM ROTATE TOGGLE SWITCH T958 JIB BOOM UP DOWN TOGGLE SWITCH 1558 PLATFORM LEVEL TOGGLE SWITCH TS60 SECONDARY BOOM UF DOWN TOGGLE SWITCH 981 PRIMARY UP DOWN TOGGLE SWITCH T562 TURNTABLE ROTATE TOGGLE SWITCH 1563 PRIMARY BOOM EXTEND RETRACT TOGGLE SWITCH JIB ROTATE TOGGLE SWITCH 2301 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 January 2015 Service Manual Ground Control Box Switch Panel Wiring Diagram AS CE from serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774
53. Specifications Machine Specifications 4 Check the pressure in each air filled tire Genie BRAND Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N 23 Part No 139378 Service Manual January 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 1 brake disengaged position 2 brake engaged position B 5 Check the Drive Hub Oil Level and Fastener Torque Genie specifications require 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 Z 34 22N Part
54. 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 boom 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 Bod
55. m J 1 ejje unius elle LVIBCI cip 5 Lal Ke oo BP1 BRN BK BK RD WH RD RD GR 2 6 0 eo 2 5 VO 1123456 9 10 7 8 DP1 2 6 4 E DO o SETUP ENABLE 4 WIRE z CR19 i ENABLE WHEN IT IS TEMPORARILY CONNECTED TO 24VDC 9 8 5 8 8 ES34DCN Part No 139378 Genie ATEREX BRAND Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N 109 Service Manual January 2015 __ _________________________ __ _______ LVI BCI Option Wiring Diagram 110 111 January 2015 Service Manual Charger Interlock Option Service Manual January 2015 Charger Interlock Option A B C D E F G H K L M C49 10 LED 1 o CHARGER 3 INDICATOR e AC AC C56 1 BK N O BATTERY 1 5 CHARGER CHARGER C56 1 BK NO 57 86 o CHARGER 1 C56 2 WH COM 24 EN 30 85 S C56 2 WH COM 2 2 5 o SUPPLY BATTERY CONTACT 17 PRI NC OPEN COIL NC CONNECT CLOSED CONNECT CONNECT 3 5 CONNECT NC OPEN 8 P P42BAT OR RD 8 48V DC 5 4 OUTPUT mo m lt u D TU 2 5 6 5 5 4 5 9 8 g
56. 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 2 34 22 Z 34 22N 35 Service Manual January 2015 Checklist D Procedures D 2 4 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 5 without operator knowledge may cause death or serious injury and property damage AWARNING Collision hazard Select a work 6 site that is firm and level Component damage hazard If the machine must be towed do not exceed 2 mph 3 2 km h Disengage the drive hubs by turning over the drive hub disconnect caps on each non steer wheel hub org 1 brake disengaged position 2 brake engaged position Manually rotate each non steer wheel Result Each non steer wheel should rotate with minimum effort 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 Fai
57. 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 terminal 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 Service Manual January 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 cran
58. 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 January 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 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 t
59. 1 wem 5 o FI MEO L ER _ 4 441 4800 psi 1600 psi i psi i E P e n 10 bar 110 bar 1 lt H 1 7 e um SEIT EID EID 10 MICRON Mo 100 MESH X tpe 47 0 8 gpm Y 0 X K 1 T 2 H X a X HYDRAULIC RESERVOIR 5 Ti FUNCTION MANIFOLD Genie 116 ATEREX BRAND Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N Part No 139378 EXTENSION CYLINDER Z30NRJ 117 January 2015 Electrical Schematic ANSI CSA AS before serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 C28JSH RD WH C32SL WH RD 1 C30FWD WH January 2015 5 E E P24BAT WH GR WH RD RD GND BR 58400 before serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 Electrical Schematic
60. 1 1 46 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N Part No 139378 2015 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 contact the Genie Product Support E 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
61. 13 Electrical contactors B 14 Hydraulic oil analysis B 15 Emergency power system Genie BRAND Z 30 20N Z 30 20N RJ 2 34 22 2 34 22 Comments Part No 139378 January 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 possible 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 man
62. 20 0 0 10 20 30 40 50 Ambient air temperature 1 Chevron hydraulic oil 5606A 2 Petro Canada Environ MV 46 3 UCON Hydrolube HP 5046D 4 Chevron Rando HD premium oil MV Genie BRAND Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N 3 Part No 139378 Service Manual January 2015 Specifications Chevron Rando HD Premium 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 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 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 Fl
63. BATQND OR BK CA7JRR coms 15 66 P JIB ROTATE RIGHT Z30N RJ ONLY RID WH CRS 48 RDWH MH RDWH SP BRAKE RELEASE RASBRK m ERR EE Teu JE ROTATE LEFT RE ONIY ORIRD CRI ORIRD C B 4 42 649 10 OR RD LS SWITCHED 48V R42BAT pum mm us Ta dE DOR 16 sueco BL K C1B 11 7 BL BK NH STEER RIGHT ca7scw Sail wae TA Bon STEER LEFT 00 C40LS C522 49 0 CH OFF LIMIT SPEED RD CR8 RD CIB 1 27 RD SP AUXILIARY PUMP C27AUX WR ar Ces ci iovenicK Fem 10 1 BK C32 4 22 4 424V TO PLATFORM P22BAT m me mum 7 GRAWH CRS 19 GR WH MH LIFT PUMP CieLPE m csi meus GRAWH C4B 7 19 GR WH SP LIFT PUMP asc Swine ORIRD CH ORIRD 048 4 18 OR RD CR5 DRIVE ENABLE Ci8DE 4 m ADEM OR BK CAB 3 15 OR BK MH OR BK SP PLATFORM LEVELDOWN _ aak mum case TR PUXTEORM ROTATE EIGHT CARS 14 OR MH OR SP PLATFORM LEVEL UP Ci4PLU p 78 57 SP ROTATE BLANH 12 FOOTSWITGH C12FTS 8 BURD DRIVE ENABLE LIGHT BL BK C3B 11 11 BL BK MH BL BK SP SECONDARY BOOM DOWN 11 BD BORD m me pom 10 Bu HORN a BL MH ELAR SECONDARY BOOM UP RDWH Cab CA1 86 CR2 86 48V RELAY COIL POWER Caps BKWHMH PRIMARY BOOM RETRACT 8 BL WH 132 GiB 12 Caza PLATFORM OVERLOAD I
64. 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 additive 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 Hydraulic Fluid Temperature Range 3 4 EE ES 40 22 4 14 32 50 68 86 104 122 F 40 30
65. JIB BOOM DOWN PLATFORM ROTATE RIGHT PLATFORM ROTATE LEFT PLATFORM LEVEL PLATFORM LEVEL DOWN PRIMARY BOOM EXTEND PRIMARY RETRACT PRIMARY BOOM UP PRIMARY BOOM DOWN SECONDARY BOOM SECONDARY BOOM DOWN TURNTABLE ROTATE RIGHT TURNTABLE ROTATE LEFT Service Manual January 2015 ___ _ __________________________ __ ___ ___ Electrical Schematic ANSI CSA from serial numbers Z30N10 12119 Z34N10 8857 and 23410 7774 140 141 January 2015 Service Manual tt Ground Control Box Terminal Strip Wiring Diagram ANSI CSA from serial numbers Z30N10 12119 Z34N10 8857 and 23410 7774 Service Manual January 2015 Ground Control Box Terminal Strip Wiring Diagram ANSI CSA from serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 142 A L84 SECONDARY UP DOWN 153 DRIVE ENABLE LS2 PRIMARY UP DOWN 151 PRIMARY EXTEND RETRACT CABLE 2 CABLE 3 CABLE MANIFOLD HARNESS MH B C11 00000 C3B 000000 000000 00000 C D E TERMINAL BASE H K WIRES FROM CONNECTOR TO CONNECTOR
66. 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 hours Semi annually or every 500 hours 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 Maint
67. No 139378 2015 Service Manual n 2 7 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 Test the Ground Control Override Genie specifications require that this procedure be 4 eH ve pup performed every 250 hours or quarterly whichever Check the torque of the drive hub mounting comes first bolts Refer to Specifications Machine A Specifications A properly functioning ground control override is essential to safe machine operation The ground 6 Repeatthis 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 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 Turn the 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 January 2015
68. PRIMARY 4 UFTPUMP 8 8 8 c d 4 3 AUXILIARY EEE LIFT PUMP 5 5 d TELEF 5 9 3 SERES 511122 9 139378 Genie Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N 148 Service Manual Electrical Schematic AS CE CO29JSH RD WH CISL WH RD WH BK WH from serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 January 2015 O29JSH RD WH 632 51 WH RD C31REV WH BK C30FWD WH P24BAT WH 5 O7P 3 BATGND BRN V C78 8BATGNDBRN OISDELBLRD 08 C82 DRIVE ENABLE 4 C9P 12 CT2DE BLWH C9B 12 ___ BK 5 d ADS 2081 DRIVE ENABLE i gt LIMIT SWITCH 4 1 4 we E i AL TRAVEL ALARM Hoe Pat 4 amp
69. SPEED CONTROL CaB 5 5 WHIBK MH WHIBK SP TURNTABLE ROTATE RIGHT C5TRR WHC3B 4 4 WH MH WH SP TURNTABLE ROTATE LEFT C4TRL RD BK CaB 2 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 B A RD 27D TO TERMINAL BASE ELE GR WH 19C AND RELAY BLOCK OR RD C48 2 GR WH C49 11 1 GR2 H GR4 H RDWH CSB 3 OR RD 42D BKRDC3BO ___ 0481 RD WH 48D RD BK C49 2 1 OR RD 16A 834000 Genie ATEREX BRAND Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N Part No 139378 WIRES CIRCUITS FROM To DESCRIPTION WH MH cioa 4 181482 JUNCTION BK gt cia 52 1 1521 54 JUNCTION OR BK 028 3 18 66 BP JIB ROTATE RIGHT Z30NRJ ONLY 23 2 73 86 SP JIB ROTATE LEFT 230NRJ ONLY 6 TS 58 SP JIB DOWN an C43JU C2B 5 TS 56 SP JIG UP oR 2 2 049 9 CH OFF LIMIT SPEED WHRD CIJEL 46 6 CH JOYSTICK POT LOW WH BK C81REV CiB 5 049 5 CH REVERSE WH C30FWD 040 4 CH FORWARD RDAWH C29J8H C49 3 CH 2 WIRE RD BK 28 2 ALARM anak C18PRR amp TS 57 SP PLATFORM ROTATE RIGHT GR CI7PRL CABS TS 57 SP PLATFORM ROTATE LEFT BL RD CI3DEL C4B 1 DRIVE ENABLE LIGHT BKRD CoHRN HORN RDAWH 8 CRI 86 86 48
70. Z 34 22N Part No 139378 2 30 20 2 30 20 January 2015 AD w Table of Contents Electrical Schematics ANSI CSA AS 117 Electrical Schematic ANSI CSA AS before serial numbers Z30N10 12119 Z34N10 8857 and 73410770 mem 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 Control Box Wiring Diagram ANSI CSA AS before serial numbers Z30N10 12119 Z34N10 8857 23410 7774 126 Electrical Schematics CE Models eene 127 Electrical Schematic CE before serial numbers Z30N10 12119 Z34N10 8857 and 23410 70 128 Ground Control Box Terminal Strip Wiring Diagram CE before serial numbers Z30N10 12119 Z34N10 8857 23410 7774 132 Ground Control Box Switch Panel Wiring Diagram CE before serial numbers Z30N10 12119 Z34
71. carefully considered for future printings of this and all other manuals Contact Us Internet www genielift com E mail awp techpub terex com Genie 1 Z 30 20N 2 30 20 RJ 2 34 22 2 34 22 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 B2 January 2015 Third Edition Second Printing Genie is a registered trademark of Terex South Dakota Inc in the U S A and many other countries 2 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 Reference Examples Section Maintenance B 3 Electronic Version Click on any content or procedure in the Table of Contents to view Section Fault Codes All charts the update Section Repair Procedure 4 2 Section Schematics Legends and schematics Genie BRAND Part No 139378 Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N iii January 2015 Introduction Revision History Revision Date Section Procedure Page Description Reference Example
72. circuit connected to the terminal on the motor controller Part No 139378 Genie BRAND Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N 97 January 2015 24 42 4 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 sure the battery to motor controller charger is more than 55V DC 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
73. crane leveling link pivot pin at the upper pivot and just enough to relieve the pressure on the twist to remove the pin 0 pin 11 Swing the leveling link up out of the way and 5 Remove the counterweight cover fasteners secure it from moving as 12 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 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 Pere ne Trove Mle IMs 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
74. of the boom A WARNING Crushing hazard The boom 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 January 2015 Service Manual 6 Support and slide the extension tube out of 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 pr
75. 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 Wheels chocked All external AC power supply disconnected from the machine Boom in the stowed position Turntable secured with the turntable rotation lock e 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 Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N Part No 139378 2015 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
76. 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 Turn the 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 0 1 Part No 139378 2 30 20 Z 30 20N RJ Z 34 22 2 34 22 27 Service Manual January 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 obstructi
77. range of temperature 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 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 January 2015 Service Manual Observe and Obey V Troubleshooting and repair procedures shall Schematics About This Section There are two groups of schematics in this section Electrical Schematics A WARNING Electrocution burn hazard 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 V Immediately tag and remove from service a damaged or malfunctioning machine V Repair any machine damage or malfunction before operating the machine Before Troubleshooting Read understand and obey the safety rules and operating instructions in the appropriate operator s manual on your machine V Be sure that all necessary tools and test equipment are available and ready for use Hydraulic Schematics A WARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to
78. 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 Indicates a potentially hazardous situation which if not avoided could result in death or serious injury A WARNING Indicates a potentially hazardous situation which if not avoided may cause minor or moderate CAUTION 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 Be sure to keep sparks flames lighted tobacco away from flammable and combustible materials like battery gases and engine fuels Always have an approved fire extinguisher within easy reach Be sure that all tools and working areas are properly maintained and ready for use Keep work surfaces clean and free of debris that could get into machine components and cause damage Be sure forklift overhead crane 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 gt injury sure to prope
79. 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 Specifications 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 8 Tagand 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 hyd
80. the foot switch and move the primary boom toggle switch in the down direction Note how long it takes to reach 0 65A January 2015 10 Set the ramp rate Turn the ramp rate trimpot 11 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 multimeter 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 January 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
81. 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 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
82. then the tire and wheel assembly Torque the wheel lug nuts to specification Refer to Specifications Machine Specifications lt o 44 Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N Part 139378 January 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 Repair any machine damage or malfunction before operating the machine Before Repairs Start 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 produce hazardous conditions Use only Genie approved replacement parts Read each procedure completely and adhere to the instructions Attempting shortcuts may 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 e All external AC power supply disconnected from the machine e the stowed position e Turntable secured with
83. way V Primary boom up down 20 25 ft Ibs 27 34 Nm 23 Flow regulator valve 1 5 5 7 L min Turntable rotate circuit 20 25 ft lbs 27 34 Nm before serial number 10808 Flow regulator valve 1 8 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 2 34 22 Part No 139378 Manifolds January 2015 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N 81 Part No 139378 Service Manual January 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 Connecta 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 o
84. 0 20N Z 34 22 Z 34 22N Part No 139378 January 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 10 that your air temperature increases or decreases from 68 F 20 Valve Coil Resistance Specification Description Specification serious injury Remove all rings valve IL 4 22 Q watches and other jewelry EMSA seo 1 Tag and disconnect the wiring from the to Proportional solenoid valve 24V DC 19 5 Q be tested schematic item H Solenoid valve N C poppet 20V DC 2350 2 Testthe coil resistance schematic item M Coils with 2 terminals Connect the leads Solenoid valve N O poppet 20V DC 23 50 from the ohmmeter to the valve coil terminals schematic item P Coils with 1 terminal Connect the positive lead from the ohmmeter to the valve coil termi
85. 0 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 Bolt torque sequence January 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 comes 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 Geni
86. 01 5 Manifold Component 5 Machine Torque 6 Hydraulic Hose and Fitting Torque 7 Torque ProcedUte trn tttm Er nnd dnte Re 8 SAE and Metric Fasteners Torque 10 Genie viii 2 30 20 Z 30 20N RJ 2 34 22 Z 34 22N Part No 139378 January 2015 AD H Table of Contents M 11 Pre Delivery Preparation 14 Maintenance Inspection 16 Checklist 17 1 Inspect Manuals and 17 2 Perform Pre operation 18 3 Function Tests eee ete p 18 4 Perform 30 Day 19 5 Grease the Turntable Rotation Bearing and Worm Drive 19 6 Replace the Drive Hub 00000 20 Checklist 21 3 1 Inspect the Battery cer eed dog 21 B 2 Inspect the Electrical Wiring 22 5 5 Inspect the Tires Wheels and Lug Nut
87. 0N10 12119 234N10 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 ci 000000 000000 000000 000000 0 D E January 2015 A 7 H M Mne F H K TERMINAL BASE TB DESCRIPTION CIRCUIT amp WIRES FROM CONNECTOR TO CONNECTOR RD WH FLASH 134 RD C32 1 KEYSWITCH POWER P184BAT WIRES CIRCUITE FROM DESCRIPTION RD WHETILT WH C7B 2 194 RD He RD KSI 4 KEYSWITCH POWER P1a4BAT WH n C102 cha 181 182 JUNCTION BR CB2 BK FLASH BEACON 52 BR MH BR CR4 GROUND BATGND BK J2 otis 052 1 182 184 JUNCTION 2 BR 78 8 52 BR BR SP GROUND
88. 1L 71 Tsee C AIRE 5 Te T559 1865 FUNCTION ENABLE TOGGLE SWITCH PE 1657 PLATFORM ROTATE TOGGLE SWITCH ORA 5 GN BK 18A 6 6 7658 _ JIB BOOM UP DOWN TOGGLE SWITCH 4 aene 1559 PLATFORM LEVEL TOGGLE SWITCH Bs d m TS60 SECONDARY BOOM UP DOWN TOGGLE SWITCH 2 d TS61 PRIMARY UP DOWN TOGGLE SWITCH Bk zoo ET a A T858 1657 T6682 TURNTABLE ROTATE TOGGLE SWITCH RDIBI2A pe AQP 0 ooo 1863 PRIMARY BOOM EXTEND RETRACT TOGGLE SWITCH EFE 9 1568 JIB ROTATE TOGGLE SWITCH 230 RJ ONLY els WHIBICSA EO 6 CIRCUIT BREAKER CONTROLS 10A 5 8 WH 4A Es CIRCUIT BREAKER CONTROLS RETURN 10 ui B 5 5 5 099 HM Me a 1560 1562 CH CHASSIS HARNESS CORP MANIFOLD HARNESS SP SWITCH PANEL BL 10A o0 cA CONTROL RELAY opoo oo TRAVEL ALARM 11814 56 7 H4 DESCENT ALARM NER 1 H6 PLATFORM OVERLOAD X DESCENT ALARM WIRING 13 CONTROLLER STATUS LED 145 PLATFORM OVERLOAD LED ES34DCT U33 Genie ATEREX BRAND Part No 139378 Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N 133 Service Manual January 2015
89. 2 RIGHT C47 CI7PRLOR us 3 5 Peta is CIBPRRBL 5 det cre CIBPRRGHBK PS 7 _ 9 ces UP 7 3 5 n 52 DOWN Te 1 14 CI4PLU cape 1 ces CIBPLDORIBK C4B8 1 EXTEND E E 4 BE In Rag 8 RETRACT 5 1 1 _ 8 C8PBR BK WH E AD A E ts 8 A 1 1 CIPBU RD Cope C2PBD RDBK P t 2 5 4 9 4 5 BLEK 4 53 Ag oom 10 CIOSBUBL 7 xx T T pibe CHSBDBLEK F j a 8 WHEK Iin 5 Has z A LEFT 8 5 CSTAR WH BK 2 1 4 C4TRLWH 084 a eer 1 x 8 1 5 g 4 a 5 E lz 29 20 ul 1 a 8 8 555 a N 119 DRIVE ENABLE LIMIT SWITCH TRAVEL ALARM BRAKE RELEASE VALVE BRAKE RELEASE VALVE BRAKE PRESSURE SWITCH STEER LEFT STEER RIGHT P HOUR METER Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N AUXILIARY PUMP PROPORTIONAL CONTROL VALVE Part No 139378 JIB BOOM UP JIB BOOM DOWN PLATFORM ROTATE RI
90. 2 21 20 19 18 17 16 15 14 13 SEE 12 1110 9 8 7 6 5 4 3 1 DETAIL A 2 GR WH 2 gt P182BAT BK P180LPR T i re 5 9 CONTACTOR 30 RELAY 85 0 GR WH ACP3 C19LPE BR EL GR WH 2 2 49 5 C31REV WH EK DETAIL A CR20 049 4 C30FWD WH RELAY SOCKET WIRING WIRE INSERTION SIDE SHOWN C48 7 C178C8L 049 9 04015 OR 049 8 C12FTS gt CIRCUIT CHANGE P182BAT BEFORE SERIAL NUMBERS 48 3 016 0 BR Z30N Z30N10 12120 734 28410 7774 ZSAN Z34N10 B858 048 2 PA2BAT OR RD C180LPR AFTER SERIAL NUMBERS ES34DCU 2301 Z80N10 12119 8 1 P182BAT RD 234 DC 23410 7773 2341 Z34N10 8857 Genie ATEREX BRAND Part No 139378 Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N 105 Service Manual January 2015 _____ ______ ____________ __ _______ Drive Contactor Panel Wiring Diagram 106 107 January 2015 Service Manual Manifold and Limit Switch Wiring Diagram Service Manual January 2015 Manifold and Limit Switch Wiring Diagram
91. 22 Z 34 22N Part No 139378 Test all machine functions from the ground controls Result All ground control functions should operate normally Using a suitable lifting device remove all test weights from the platform January 2015 Service Manual 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 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
92. 3 LO OR C2P 2 C15PLD OR BK C4P 3 C8PBR C8P 8 BK C3P 7 Ci3DEL BL RD 1 ORG RD BRN C378CW C1P 11 036800 10 RD 4 066 NOO O O4 NC P3 P2 BCI 24 WH C9P 2 DP1 WH 4 G31REV WH BK 1 5 632081 WH RD C1P 6 1123456789110 C29J8H RDWH C1P 3 3 R42BAT OR RD C2P 4 P26BAT BK 9 1 22 BK C7P 1 C9HRN BK RD C3P 9 C27AUX RD C17PRR BL 47 2 C18PRLOR C47 1 C44JD WH C47 3 C43JU BK C47 4 47 5 RD 47 6 WORK LIGHTS OPTION 2308 RJ MODELS JIB ROTATE Z30N RJ MODELS Genie Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N Part No 139378 126 127 January 2015 eee ee Electrical Schematic CE before serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 January 2015 Service Manual Electrical Schematic CE before serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 RDWH
93. 37 Adj Non adj 85 ft lbs 115 3 Nm 12 All types 135 ft lbs 183 Nm 16 All types 200 ft lbs 271 2 Nm 20 All types 250 ft lbs 339 Nm 24 All types 305 ft lbs 413 5 Nm Genie BRAND Part No 139378 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 tight 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 January 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 ma
94. 4 L min 5 Orifice plug 0 025 inch 0 64 mm AE Jib boom rotate circuit located under plug Models with rotating jib boom Part No 139378 Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N AD WS ILD SS SSX e OY 5 lt 012 LE 5 Models without rotating jib boom Genie BRAND 85 Service Manual January 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 ltem 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 ft 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 4 AD ES BJ JE e 2 2 De S 5 4 Models with rotating jib Models without rotating jib Gri o 86 Z 30 20N Z 3
95. 46JRL OR C2P 2 WH 0 D 0 E pre LO 1 1 1 1 1 1 C15PLD OREK C4P 3 BK WH 8 C7PBE BK C3P 7 C13DEL BL RD C4P 1 C378CW BLK C1P 11 036900 BL 10 BRN ORGRD P24BAT WH C9P 2 RD C30FWD WH 4 WH BK C1P 5 032381 WH RD C1P 6 C29J5H RD WH C1P 3 1 2 8 4 5 6 7 8 9 10 51 O 5 066 NO LO NC O4 NC DP1 C3P 3 R42BAT OR RD 2 4 P26BAT BK C9P 1 P22BAT BK C7P 1 C9HRN BK RD 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 Z 34 22 Z 34 22N 146 147 January 2015 Enn Electrical Schematic AS CE from serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 C29JSH January 2015
96. 49 7 pS UD BR C48 3 OR RD 42A WH BK 19C 48C C32 12 T O NCO 1 TO TERMINAL BASE HM 3 AND CONNECTORS i RD C48 1 CB2 TS51 PO 1 RD 194A 4 BK 22A RD C23 6 RD 27A 15 BK 7A BK WH 8A LABEL DESCRIPTION WH RD GA P1 EMERGENCY STOP BUTTON o pope FL 863 1859 JIBROTATE 1 KEY SWITCH MODELS 1 5 dea Po d4 d j 4 1851 AUXILIARY TOGGLE SWITCH 1888 b M 5 55 _ FUNCTION ENABLE TOGGLE SWITCH gt 7 _ PLATFORM ROTATE TOGGLE SWITCH ER TS58 JIBBOOM UP DOWN TOGGLE SWITCH 4 5 1559 PLATFORM LEVEL TOGGLE SWITCH E 6 S57 78860 SECONDARY BOOM UP DOWN TOGGLE SWITCH me D D 0 g 6 _ PRIMARY BOOM UP DOWN TOGGLE SWITCH BK220 dou Ou Qe 2 1562 TURNTABLE ROTATE TOGGLE SWITCH akeri SS TS63 PRIMARY BOOM EXTEND RETRACT TOGGLE SWITCH _ E 7566 JIB ROTATE TOGGLE SWITCH Z30NRJ ONLY 6 CIRCUIT BREAKER CONTROLS 10A 8 5 8 Eu ms CIRCUIT BREAKER CONTROLS RETURN 10A 5 TS60 TE e c HM HOURMETER E m a BLBK 11A Qu CH CHASSIS HARNESS AD C32 7 MH MA
97. 52 2 WH ic cma 4 CRIBA 9 re re 9 9 E 2 D C21 1 C20 1 A A 2 C20 2 e e e GROUND BR ru mu aS 2 SCHEMATIC PLATFORM LEVEL CUTOUT ES0276N January 2015 Service Manual CTE Option CE Models L G H K M BR 1 CR18A CR18B PLATFORM LEVEL UP PLATFORM LEVEL DOWN 2 BR C15PLD OR BK C21 1 C14PLU C20 1 3 C40LS1 OR CR18A 30 C14PLU OR 2 OR TS59 C14PLU OR 18 86 ORTSS 14 PLATFORM LEVEL UP uc S 15 PLATFORM LEVEL DOWN 15 CRISBASS 5 P22BAT BK 32 4 P22BAT BK KSI 2215 BK 10 1 E SAV TO PLATFORM gt 6 e P134BAT RD LS17 38 1 5 134 LOAD WEIGHING LIM SW 12 1 4 x PISABAT BICLSS 37 3 I 134 WH FH 7 134 LOAD WEIGHING UM SW 127 2 134 O PIS4TTSRDA GROUND BOLT 8 WIRING DIAGRAM x Genie Part No 139378 Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N 113 Service Manual January 2015 ___ _______________ ______ __ _______ Option CE Models 114 115 January 2015 Service Manual Hydraulic Schematic Service Manual Januar
98. BOOM DOWN 198 5 ay EY YE 235 ra 1 1 oR DESCENT pague 9 CIOSBUBL C3B 10 az ALARM C Jo 1 DOWN 8 RIGHT WHIBK n 4 TURNTABLE E ROTATE RIGHT BE ot WH n TURNTABLE 55 a ROTATE LEFT pels 2 1 29 RIGHT GaP 5 OBTRR WH BK 088 5 1 03 4_ gt WH 0884 LEFT 4 4 ER 4 nr 925 2 12 888 4 tl BK E a lI DRIVE LIGHTS 5 WH gt BK OPTION on 1888 52 2 i WH 2 11 WORK LIGHTS 1 PABLPS WH _ 48LPS C2P 10 1 T 5 ae SE 81 als 55 823 Etc 10 i lt PE 5 8 8 gu ging 1 ead 066 S 6 1 149 gt Z 30 20N 2 30 20 RJ 2 34 22 Z 34 22N Part No 139378 Service Manual January 2015 ___ _ ______________________ _ ___ ___ Electrical Schematic AS from serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 150 151 January 2015 Service Manual 1 Ground Control Terminal Strip Wiring Diagram AS fr
99. GHT PLATFORM ROTATE LEFT PLATFORM LEVEL uP PLATFORM LEVEL DOWN PRIMARY BOOM EXTEND PRIMARY BOOM RETRACT PRIMARY BOOM UP PRIMARY BOOM DOWN SECONDARY BOOM UP SECONDARY BOOM DOWN DESCENT ALARM TURNTABLE ROTATE RIGHT TURNTABLE ROTATE LEFT Service Manual January 2015 ___ _ _________________ ___ _ __ __ Electrical Schematic ANSI CSA AS before serial numbers Z30N10 12119 Z34N10 8857 and 23410 7774 120 121 January 2015 Service Manual Ground Control Box Terminal Strip Wiring Diagram ANSI CSA AS before serial numbers Z3010 12119 Z34N10 8857 and Z3410 7774 Service Manual January 2015 Xa mm Y n Ground Control Box Terminal Strip Wiring Diagram ANSI CSA AS before serial numbers Z3010 12119 Z34N10 8857 and Z3410 7774 A B C52 1 154 SECONDARY o UP DOWN 133 ENABLE ci 182 PRIMARY 2 UP DOWN o o C10 181 PRIMARY o EXTEND RETRACT CABLE 2 C7B gt 4 000000 000000 CABLE 3 000000 C3B 000000 000000 C2B 5 000000 CABLE 000000 7 MANIFOLD HARNESS MH C48 000 CHASSIS HARNESS CH C49 8 000000 122
100. N TOGGLE SWITCH 9 9 e 9 e 9 e 9 9 9 TURNTABLE ROTATE TOGGLE SWITCH E 8 8 5 8 5 5 4 8 3 8 9 5 3 e 33 8 i 8 9 o d d B E 8 8 _ TOGGLE SWITCH m 5 gt 8 8 np 2 5 B mic 5 5 5 2 2 B 2 5 mg A gt E DRIVE ENABLE TOGGLE SWITCH 4 2 2 8 8 5 919 a 9 go a 3 o gp a 1616 JIB ROTATE TOGGLE SWITCH 230 RJ ONLY Ble d 8 e BRERBES B Eo 8 2 5 8 oo 9 5 8 H m DRIVE ENABLE LED E a g v 0 70 2 g g S 2 mr T 5 T P a E m PLATFORM OVERLOAD LED 148 TURNTABLE TILT ALARM LED OPTION RELAY N O WORK LIGHTS OPTION ESS4DCT JIB ROTATE WORK LIGHTS OPTION RJ ONLY 230 RJ MODELS 137 January 2015 oes oooHTTTSTSXTTTTHYTTHSYYYSSHS XXSHHSH a Electrical Schematic ANSI CSA from serial numbers Z30N10 12119 Z34N10 8857 and 23410 7774 January 2015 Service Manual Electrical Schematic ANSI CSA from serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 29 5 RD WH
101. N10 8857 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 January 2015 gt 7 Table of Contents Electrical Schematics ANSI and CSA 137 Electrical Schematic ANSI CSA from serial numbers Z30N10 12119 Z34N10 8857 and 23410 7774 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 Platform Control Box Wiring Diagram ANSI CSA from serial numbers Z30N10 12119 Z34N10 8857 and 23410 7774 146 Electrical Schematics AS CE Models eene 147 Electrical Schematic AS CE from serial numbers Z30N10 12119 Z34N10 8857 and 23410 7774 148 Ground Control Box Terminal Strip Wiring Diagram AS CE from serial numbers Z30N10 12119 Z34N10 8857 and 23410 7774
102. NG 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 Rotate the turntable to either side until the boom is centered between the steer and non steer tires 2 Raisethe 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 grad
103. NIFOLD HARNESS SP SWITCH PANEL d 5 BL 10A CR CONTROL RELAY d H3 TRAVEL ALARM 3 6 7 8 12 2 4 DESCENT ALARM OPTION Eu 1 13 CONTROLLER STATUS LED ES34DCT Genie ATEREX BRAND Part No 139378 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N 123 Service Manual January 2015 pm SnM Ground Control Box Switch Panel Wiring Diagram ANSI CSA AS before serial numbers Z30N10 12119 Z34N10 8857 and 23410 7774 124 125 January 2015 Service Manual Platform Control Box Wiring Diagram ANSI CSA AS before serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 January 2015 Platform Control Box Wiring Diagram ANSI CSA AS before serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 PLATFORM CONTROL BOX i JIB WORK LIGHTS OPTION WH Ch45 5 le P48LPS WH RD C1P 9 C47 WH RD T349 BAN JIE 2 34 22 MODELS THIS LOCATION IS USED FOR 2 TS49 WORK LIGHT OPTION gt TURNTABLE TILT ALARM LED OPTION NOTES BAIN2 DESCRIPTION RELAY WORK LIGHTS OPTION EMERGENCY STOP BUTTON HORN BUTTON
104. NING AWARNING A CAUTION Part No 139378 January 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 machine 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 Genie BRAND Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N 71 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
105. NING 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 January 2015 Service Manual 51 A WARNING 52 53 55 AWARNING 56 Part No 139378 Secondary Boom Components 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 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 Attach a lifting strap from an overhead crane to the mid pivot for support 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 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 Remove the mid pivot from the machine Crushing hazard The mid pivot could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane Remove the secondary boom drive speed limit switch LS4 mounted to the turntable riser on the ground controls side Do not disconnect the wiring Gen
106. NING Crushing hazard The primary boom lift cylinder could become unbalanced and fall if not properly supported by the lifting device 25 Lower the rod end of the primary boom lift cylinder onto support blocks Protect the cylinder rod from damage 26 Remove the pin retaining fastener from the primary boom pivot pin 27 Remove the primary boom pivot pin with a soft metal drift Carefully remove the primary boom assembly from the machine AWARNING Crushing hazard The primary boom could become unbalanced and fall when removed from the machine if not properly attached to the overhead crane 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 2 Place blocks under the extension cylinder for support 3 Remove the retaining fasteners from the extension cylinder barrel end pivot pin Use a soft metal drift to remove the pin 4 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 5 Support the extension tube with an overhead crane at the platform end
107. NPUT BK C97 Bun PRIMARY BOOM EXTEND 01330 1 1466 PLATFORM OVERLOAD ALARM WH RD C3B 6 6 WH RD MH WHIRD SP FUNCTION SPEED CONTROL C MFV ORB mp pum aay ROWER WH BK 5 5 WH BK MH WHIRK SP TURNTABLE ROTATE RIGHT C5TRR nm pun 242 DRAKE RELEASE 4 WH MH WHSP TURNTABLE ROTATE LEFT _G47AL RD 1 10 88 88 PLATFORM LEVEL CUT OUT RD BK 2 RD BK SP PRIMARY BOOM DOWN C2PBD RD 1 1 RD MH RD SP PRIMARY BOOM UP D 0 4 C2B 12 RD 27D L29 TO TERMINAL BASE SS GR WH 19C WH AND RELAY BLOCK OR RD C48 2 GR AWH C49 11 BIC22A GND BR cR2 H H BR 52A ABS CR23 RD WH C3B 3 448 00 Fig RD BK RD MH HORN DRIVE LIGHTS OPTION OR RD 42D BK RD C3B 9 RD C49 1 CONTROL RELAY 1 0 RD WH 48D CR1 SECONDARY 48V POWER CR2 PRIMARY 48V POWER CR5 CR3 AUXILIARY PUMP FS CR4 HORN RD BK C49 2 5 BRAKE RELEASE CR23 DRIVE LIGHTS OPTION OR RD 16A ES34DCT Genie ATEREX BRAND Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N Part No 139378 REF 86 85 87A 87 RELAY SOCKET SHOWN January 2015 Service Manual Ground Control Box Switch Panel Wiring Diagram CE before serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774
108. OR RD 2 4 OR RD 649 10 OR RD La SWITCHED 48V FEN BA m 1 11 37 BL BK MH STEER RIGHT 375 6 BLCIB 10 36 BL MH STEER LEFT 65 SR T sv L92 PRIMARY C40L8 6522 049 9 CH OFF LIMIT SPEED UP DOWN RD CRS RD C1B 1 27 RD SP AUXILIARY PUMP CO7AUX 2 GT 649 6 CH JOYSTICK POT LOW 80101 024 BKcnt WH BK CB REV 0185 049 5 CH REVERSE 8 19 GR AWH SP LIFT PUMP Cia PE m Sean cux mo EDWARD 151 PRIMARY 4 emen GRMH CAB 7 19 GR WHAMH LIFT PUMP EXTEND RETRACT 5 RD WH 040 3 CH 2 WIRE POT 68 1 6484 s OR RD CRS DRIVE ENABLE mm ETE ga Sing OR BK C4B 3 5 OR BK MH ORBK SP PLATFORM LEVEL DOWN _ C15PLD CEAR Bea HSE OR 5 OR MH PLATFORM LEVEL UP C14PLU p e cine m ROTATE mE BUWH 38 12 BLAWH CH BLAD C4B 1 DRIVE ENABLE LIGHT BLBK 036 11 Tl BLBK SP SECONDARY BOOM DOWN 011580 10 8 SEODNDARYBOOMUP C10SBU m m mE mE BLMH RDWH CRI 86 6 48V RELAY COIL POWER BKWH 8 PRIMARY BOOM RETRACT BLIWH 1 C1BA2 032 8 PLATFORM OVERLOAD INPUT BK C357 BK MH BKSP PRIMARY BOOM EXTEND 2 1456 PLATFORM OVERLOAD ALARM 2 WH RD 6 WH RD MH
109. RD C3B 9 RD C48 1 GONTROL RELAY 1 0 RD WH 48D CR1 SECONDARY 48V POWER CR2 PRIMARY 48V POWER CRS CR3 AUXILIARY PUMP CR4 HORN RD BK C49 2 CR5 BRAKE RELEASE CR23 DRIVE LIGHTS OPTION OR RD 16A Genie Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N Part No 139378 RELAY SOCKET SHOWN N DESCENT ALARM WIRING 1551 1959 TS57 g January 2015 Service Manual Ground Control Box Switch Panel Wiring Diagram ANSI CSA AS before serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 eee 1 RD WH 48A jets TILT SENSOR WH RDIBK C1B2 52 8 SWITCH PANEL 9 L3 2 89 526 fs
110. RNING 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 RJ 2 34 22 Z 34 22N Part No 139378 January 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 AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 2 Close the 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
111. ROTATE Z30N RJ MODELS 2 QR 14A GN BK 18A GN WH 19A GN BK 44A BL WH 2 BK22C GN 43A 9v 9090 1 HMA RD 1A BR 5 SV OD 0 m 5 TS60 FI BL BK 11A RD O32 7 BL 10A S D E SENSOR ap ADHD Bk P L3 BR 52D Dy ces d D BR C48 3 ORRD 42A LABEL DESCRIPTION P1 EMERGENCY STOP BUTTON 1 KEY SWITCH TS51 AUXILIARY TOGGLE SWITCH 7855 FUNCTION ENABLE TOGGLE SWITCH T557 PLATFORM ROTATE TOGGLE SWITCH TS58 JIB BOOM UP DOWN TOGGLE SWITCH TS58 PLATFORM LEVEL TOGGLE SWITCH 0 SECONDARY BOOM UP DOWN TOGGLE SWITCH TS61 PRIMARY BOOM UP DOWN TOGGLE SWITCH T862 TURNTABLE ROTATE TOGGLE SWITCH TS63 PRIMARY BOOM EXTEND RETRACT TOGGLE SWITCH TS66 JIB ROTATE TOGGLE SWITCH Z30NRJ ONLY CIRCUIT BREAKER CONTROLS 10A CIRCUIT BREAKER CONTROLS RETURN 10A HM HOURMETER CHASSIS HARNESS MH MANIFOLD HARNESS SWITCH PANEL CONTROL RELAY H3 TRAVEL ALARM H4 DESCENT ALARM OPTION L3 CONTROLLER STATUS LED
112. Switch to either side and move and hold the turntable rotate toggle switch in the right 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 Repeat steps 2 and 3 to confirm the relief valve pressure setting 7 Remove the pressure gauge Gri 1 1 1 1 1 1 1 84 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N Part No 139378 January 2015 Service Manual 7 3 Manifolds 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 Description Function Torque 1 Solenoid valve 3 position 4 way AA Jib boom up down 20 25 ft Ibs 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 ft lbs 27 34 Nm 0 3 gom 1 1
113. V RELAY COIL POWER OR RD CRZ 80 048 2 48V POWER RD BK CABBRK CRS 85 C492 BRAKE RELEASE C2B 12 WH 129 WH 1 1 BR 52A GR23 48V DC AD BK RD MH HORN JA DRIVE LIGHTS OPTION CONTROL RELAY SECONDARY 48V POWER CR2 PRIMARY 48 POWER GR3 AUXILIARY PUMP HORN CRS BRAKE RELEASE CR23 DRIVE LIGHTS OPTION REF 6 87 i 87 gt RELAY SOCKET SHOWN 8 6 o 52 1 ONCO O NCO T551 TS66 1559 C OR TS58 1957 OR O O OR TS62 TS55 DESCENT ALARM WIRING January 2015 Service Manual Ground Control Box Switch Panel Wiring Diagram ANSI CSA from serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 H K L M RD WH 48A BR 52A SWITCH PANEL O O WH BK 18C 48C BR C32 12 ONCO TO TERMINAL BASE O NGO HM AND CONNECTORS RD C48 1 2 RD 134A BK 22A RD C23 6 RD 27A OR BK 15A 7 BK WH 8A WH RD 6A OR BK C2 3 _ JIB
114. VES m m SCHEMATIC ITEM RATIO PRESSURE ROTATE MANIFOLD nl ud mw O ew uq o ROTATE MANIFOLD PLATFORM 2 BF BG BH a 2500 AJ Sod ENS ENS BC BL 154 3000 PSI 8300 psi BJ BK BL BM BN B c 1 3000 PSI i 21 3000 psi L 8900 nei i 207 227 5b _ Leste BA BB 4 54 3000 PSI ARA JR2 MH PR2 BD BE 81 3200 Bl BJ BM BN 31 3306 PSI O O O eT 3 0 025 Inch CHECK VALVES P 0 635 mm AD 0 8 gpm SCHEMATIC ITEM DESCRIPTION 1 14 CA PILOT CHECK VALVE PLATFORM LEVELING SLAVE CYLINDER JIB BOOM MANIFOLD 4 EXTENSION CYLINDER Z30N 2341 23400 SECONDARY CYLINDER STEER __ 0032 inch CYLINDER mm TURNTABLE ROTATE gt Za0NRJ 2800 psi 198 ber 17 BRAKES 71 MOTOR 5 ZS4N 73400 3200 psi 221 bar 3000 3 m 207 BB 229 mm TO ae 7 8 cu inire 3 2 cA MASTER 124 5 E 1 N CYLINDER P LEON PHE Mo m MIS I LXI Lip 2500 psi L BD 172 bat 81 1 E 7 T COM 207 bat 6 2b 1 amp 1 AUXILIARY n m PS mo m o uw n a e 7 PUMP p IET IET 0 5 i Jd
115. WH RD SP FUNCTION SPEED CONTROL UE PET GU dd IV PONER WHIBK 5 WH K MH WHIBK SP TURNTABLE ROTATE RIGHT 52 CRE 486 6 WH C3B 4 4 WH MH WH SP TURNTABLE ROTATE LEFT C4TRL C3B 2 2 RD BKMH RD BK SP PRIMARY BOOM DOWN RD 0 1 1 RD 8P PRIMARY BOOM UP CiPBU D 000000 C4B 000000 000000 WH C3B 000000 RD 27D TO TERMINAL BASE GR WH 19C Ea WH mu AND RELAY BLOCK OR RD C48 2 000000 GRANH C49 11 BK 22A GND C2B BR 000000 2 1 H H GABLE 1 BR 52A cR28 000000 RD WH C3B 3 2 M8VDO pig RD 000000 BK RD MH HORN M DRIVE LIGHTS OPTION OR RD 42D BK RD C3B 9 RD C49 1 CONTROL RELAY I D CR1 SECONDARY 48V POWER ors CR2 PRIMARY 48 POWER AUXILIARY PUMP RD BK C49 2 1 HORN 5 BRAKE RELEASE OR RD 16A CR23 DRIVE LIGHTS OPTION MANIFOLD HARNESS MH REF 30 86 85 CHASSIS 87A HARNESS CH C49 87 RELAY SOCKET SHOWN ES34DCU Genie ATEREX BRAND Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N Part No 139378 BR 52A 1 ONCO ONCO 1988 1583 TS58 TS61 0 T855 8 O O 0 DESCENT ALARM WIRING j 8 O O
116. act Diode starting aid glow normally open Switch normally open normally closed normally open plug or flame ignitor Genie BRAND Z 30 20N RJ 2 34 22 Z 34 22N Part No 139378 2 30 20 100 January 2015 Service Manual Hydraulic Symbols Legend 0 037 incn 0 94 mm Orifice with size Check valve Shut off valve n Brake Pump fixed displacement Pump bi directional variable displacement Motor bi directional Motor 2 speed bi directional Double acting cylinder Filter with bypass relief valve Pump prime mover engine or motor Relief valve with pressure setting Shuttle valve 2 position 3 way Priority flow regulator valve Solenoid operated proportional valve IX Directional valve mechanically activated 50 50 Flow divider combiner valve Al as Pilot operated 3 position 3 way shuttle valve Solenoid operated 2 position 3 way directional valve Counterbalance valve with pressure and pilot ratio SI ALS DAS Solenoid operated 3 position 4 way directional valve Solenoid operated 3 position 4 way proportional direct
117. ain 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 January 2015 AI Jg 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 responsibilities manual Genie TEREX BRAND Genie UK The Maltings Wharf Road Grantham Lincolnshire NG31 6BH England 44 1476 584333 Terex South Dakota Inc USA 500 Oak Wood Road PO Box 1150 Watertown SD 57201 6150 605 882 4000 Instructions Use the operator s manual on your machine The Pre delivery Preparation consists of com
118. 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 damage 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 Part No 139378 Service Manual Manifolds 7 1 Function Manifold Components The function manifold is locate behind the ground controls turntable cover January 2015 o A Bm A ARN 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 Ibs 41 47 Nm 9 Check valve Brake circuit 10 12 ft lbs 14 16 Nm 10 Solenoid valve 3 po
119. allow the oil 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 Service Manual January 2015 Electrical Symbol Legend 1 N p z Ht Battery Coil solenoid or relay Horn or alarm Flashing beacon Gauge 1 v L3 1 25A Diode Hour meter LED Fuse with amperage Foot switch 2 153 zlo PRi 5 N O H C 8 5 9 Coil with suppression Fuel or RPM solenoid T circuits connect Limit Switch Power relay CBI TB21 ives 2 15A T circuits connect at Circuits crossing no Quick disconnect Circuit breaker with terminal connection terminal amperage 2 TS2 pue EL 9 9 gt LL rv 2 Key switch Toggle switch DPDT Toggle switch SPDT Pump or Motor Tilt sensor 2 Gi 5100 HE Horn Emergency stop button Resistor with ohm value Battery seperator Gauge sending unit open normally closed pee SW sw2 4 AMA nes N O N C N O Oil temperature switch Coolant temperature Oil pressure switch Control relay cont
120. and installed or when new hoses or fittings are SAE O ring Boss Port tube fitting installed into Aluminum all types SAE Dash Size Torque installed Seal Lok Fittings hose end ORFS 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 Ibs 249 5 Nm SAE Dash Size Torque 4 10 ft Ibs 13 6 Nm 6 30 ft lbs 40 7 Nm 8 40 ft Ibs 54 2 Nm 10 60 ft lbs 81 3 Nm 12 85 ft lbs 115 Nm 16 110 ft Ibs 150 Nm 20 140 ft Ibs 190 Nm 24 180 ft lbs 245 Nm 37 Fittings swivel nut or hose connection Adjustable Fitting 1 jam nut Non adjustable fitting SAE O ring Boss Port SAE Dash Size Thread Size Flats tube fitting installed into Steel 4 7116 20 2 SAE Dash Size Torque 6 9 16 18 1 4 ORFS 37 Adj 15 ft Ibs 20 3 Nm 8 3 4 16 1 ORFS Non adj 26 ft lbs 35 3 Nm ET 2 37 Non adj 22 ft lbs 30 Nm 6 ORFS Adj Non adj 35 ftlbs 47 5 Nm 12 1 12 1 37 Adj Non adj 29 ft lbs 39 3 Nm 16 1 5 16 12 1 8 ORFS Adj Non adj 60 ft Ibs 81 3 Nm 20 112 1 37 Adj Non adj 52 ft lbs 70 5 Nm 24 1 12 1 10 ORFS Adj Non adj 100 ft lbs 135 6 Nm
121. anging 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 switch on and activate each boom function toggle switch Note 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 Service Manual January 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
122. areas for burnt chafed corroded pinched and loose wires e Cable track on the primary boom e Primary boom to platform cable harness Inside of the platform control box 8 Inspect for 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 Component 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
123. ation Motor 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 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 Gri 1 1 1 1 1 b 90 Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N Part No 139378 January 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 pin 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 flat surface and gently pry the grease seal
124. blocks that were placed on the upper secondary boom Genie 64 Z 30 20N Z 30 20N RJ 2 34 22 2 34 22 Part No 139378 January 2015 15 Place a rod through the barrel end pivot pin and twist to remove the pin AWARNING Crushing hazard 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
125. ce 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 Rises to OL V motor controller M B Rises to OL V AWARNING Electrocution burn hazard B F1 Rises to 0L V Contact with electrically charged 22 Rises to OL 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 0L 3 Press the release tab on the motor controller harness connector and remove the motor controller harness connector from the motor controller Genie BRAND Part No 139378 Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N 93 January 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
126. d 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 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 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 2015 Service Manual Primary Boom Components 5
127. 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 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 Service Manual January 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
128. e 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 counterweight from the lower 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 leveling link AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and ADANGER The burn skin Loosen hydraulic ominienyeigni 18 connections very slowly to allow Stability i the oil pressure to dissipate counterweight is not installed gradually Do not allow oil to during reassembly of the squirt or spray machine the machine will become unstable and tip over A WAR
129. e 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 Clean the area around 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 2015 Service Manual Checklist D Procedures 6 Install the new oil filter element into the filter D 6 housing Inspect for Turntable Bearing 7 Push the 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 an
130. ectrical Schematic ANSI CSA from serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 C28JS H RD WH T N e 7 3 BATGND OTBSBATGNDBRN CHaDELBURD CAB ELAD WHE BRNS ATE 8 1 2 CIPFTBBLAWH 12 CI2FTS BL WH BKS ay 0 5 Ta gt C4B4 C16DE F 4 RDAVH 4 E 55 8 558 5 RDAWH 5 e eo g 1 55 as E 7 58 d 4 io CIP 10 096900 BL 10 E BL B car C3 8CW BLK 3 AP 11 lt G1B 11 e A 1 4 E 1 al x 5 5 5 5 m 1 a 07 v EN 4 WHIBK 88 4 84 t t ce Gi B e p IP CAUX RD
131. en 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 Gri o 92 Z 30 20N Z 30 20N RJ 2 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 SOR Toler can ave Result All desired results must 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 range repla
132. eration 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 e 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 January 2015 Service Manual B 14 Perform Hydraulic Oil Analysis Genie specifications 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 ch
133. erial number stamped on chassis 5 Serial label located under cover gt Genie BRAND Part No 139378 Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N V Service Manual January 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 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 MI You have the appropriate tools lifting equipment and a suitable workshop Gri o vi Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N Part No 139378 January 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 used to alert personnel to potential personal injury hazards Obey all safety messages
134. esult The platform overload indicator lights should be off at both the ground and platform controls and the alarm should not sound 6 additional weight to the platform that is equal to but does not exceed 15 of the maximum rated load Secure the additional weight Refer to the machine serial plate 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 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 10 Using a suitable lifting device lift the additional test weight from the platform Result The platform overload indicator lights should turn off at both the ground and platform controls and the alarm should not sound Note There may be an 2 second delay before the overload indicator lights and alarm turn off 11 Gri oy 34 Z 30 20N Z 30 20N RJ Z 34
135. f they 8 Raise the secondary boom until the primary are kinked or pinched boom lift cylinder rod end pivot pin is 3c accessible above the mid pivot weldment 20 Remove the pin retaining fastener from the master cylinder rod end pivot pin Use Turn the machine off 6 metal drift to remove the pivot pin Pull the 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 E 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 Genie _ 0 0 0 Part No 139378 2 30 20 Z 30 20N RJ Z 34 22 Z 34 22N 61 January 2015 Primary Boom Components 22 Attach a lifting strap from an overhead crane to the primary boom lift cylinder 23 Place2x4x 18 inch 5 x 10 x 46 cm support blocks under the cylinder across the secondary boom 24 Remove the pin retaining fastener from the primary boom lift cylinder rod end pivot pin Use a soft metal drift to remove the pin AWAR
136. ff Hold the system relief valve with a wrench and remove 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 Connecta 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
137. 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 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N 29 Part No 139378 Service Manual January 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 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 op
138. fore 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 2 34 22 2 34 22 Part No 139378 January 2015 Service Manual 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 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 B
139. he 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 could 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 2 34 22 Part No 139378 January 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 b
140. he overload indicator light flashes at both the platform and ground controls and the alarm sounds Proceed to step 7 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 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 lights and alarm responds 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 are 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 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 pla
141. ie BRAND Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N 49 Part No 139378 January 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 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 specificatio
142. ie BRAND 10 Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N Part No 139378 January 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 RN 5 Machines that have been out of service for a period longer than 3 months must complete the quarterly inspection Genie BRAND Machine Configuration 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
143. igh Strength THREAD Grade 5 2 Grade 8 65 indbs Nm Nm Nm in ibs Nm Nm 44 ___20 80 9 13 124 40 158 _ 130 7147 28 90 101 120 135 120 135 160 18 _ 140 158 BINE LUBED LUBED Nm ftibs Nm Nm ftibs Nm 5 Nm 546 ___18 13 176 17 23 18 24 25 339 284 24 14 19 19 257 271 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 41 745 60 813 80 1084 68 921 3 80 7 86 7 90 108 4 120 122 75 1084 110 149 93 126 110 120 162 150 203 130 16 120 162 130 176 230 140 189 203 160 217 210 284 24 170 270 366 280 378 380 515 320 433 300 406 310 420 420 569 350 474 430 583 450 610 610 827 50 691 470 637 500 678 670 908 560 759 710 962 750 1016 990 1342 840 1139 790 890 1120 1518 1360 1844 1820 2467 150 2074 1240 1979 1950 2643 2370 3213 3160 4284 2670 12 1640 2223 2190 3000 METRIC FASTENER TORQUE CHART This chart is to be used as a guide only unless n
144. ily 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 pin Use a soft metal drift to remove the pin Genie Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N AWARNING January 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 January 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
145. ing 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 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 cylinder the O ring if equipped on the fitting and or hose end must be replaced All connections must be 6 Remove the pm retaining fasteners from the torqued to specification during installation Refer to boom lift cylinder barrel end pivot pin Use Specifications Hydraulic Hose and Fitting Torque a soft metal drift to remove the barrel end Specifications pivot pin P 7 Use a soft metal drift to remove the jib boom 1 e a m qi 2 lift cylinder rod end pivot pin Remove the jib UNEEI IE NER 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 AWARNING lift cylinder may become Note Do not rest the entire weight of the boom on unbalanced and fall when it is the blocks removed from the machine if it is 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 a
146. ional valve H HH gt 2 position 2 way solenoid valve Part No 139378 Genie BRAND Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N 101 Service Manual January 2015 Limit Switch Location Legend LS1 152 e N NN Wo 154 Z 30 20N Z 30 20N RJ LS1 m x 2 7 iY M N N N bu NEED YH _ LS4 2 34 22 a 7 Ge NI 34 22N jj 4 S o 1 1 102 Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N Part No 139378 January 2015 Service Manual 14 Power Cable Wiring Diagram 103 Service Manual January 2015 Power Cable Wiring Diagram H AMMETER LEFT SIDE 1 BATTERY PACK Bk 10 WH 10 _ 4 2 BATTERY CHARGER 4 PRIMARY LIFT PUMP f 1 Di BK 4 3 0 7 ________ 8 5 m n e A 4 8 2 RD 2 B
147. is 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 wheels then center a lifting jack under the steer axle 3 Raise the 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
148. k 2 5 8 DIODES DRIVE CONTACTOR 9 F2 PRI 100A PRIMARY LIFT PUMP PR2 CURTIS SEPEX 6 MOTOR CONTROLLER NOTE WIRE GAUGE NOTED IN PAENTHESES AFTER WIRE COLOR RD 10 7 BK 2 D 7 F2 2 BK 2 3 2 ES34DCN Al 8 AD 10 Genie ATEREX BRAND 104 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N LEFT SIDE DRIVE MOTOR Part No 139378 F3 Y 100A 9 AUXILIARY LIFT PUMP CONTACTOR PR3 RD 10 A1 Fi BK 2 9 Or A2 RIGHT SIDE DRIVE MOTOR L D1 2 A2 D BK 2 5 AUXILIARY LIFT PUMP AP1 L RIGHT SIDE BATTERY January 2015 Service Manual UMM MMMM IH Drive Contactor Panel Wiring Diagram C D E F G H J K L M 049 1 R27AUX RD C49 11 19 C49 6 C32J8L WH RD C49 8 C29J8H RD WH 492 CASBRK RD BK C49 10 R42BAT OR RD 2 OR RD 2820 10 AB 24N LLJ LJ 7 CURTIS SEPEX MOTOR CONTROLLER OR RD OR RD 55 P 2 PRIMARY PR1 8 LIFT PUMP DRIVE AUXILIARY 5 CONTACTOR CONTACTOR MEE HE 2
149. l 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 Inspector title D 5 Hydraulic filters 1 1 A 6 Drive hub oil D 6 Turntable bearing Checklist B wear Instructions B 1 Battery Checklist E N e Make copies of this report to use for Be wiring E 1 Hydraulic oil each inspection B 3 Tires and wheels E 2 Wheel bearings Select the appropriate checklist s for the type of inspection s to perform every 2000 hours Place a check in the appropriate box after each inspection procedure is completed Use the step by step procedures in this section to learn how to perform these inspections If any inspection receives an tag and remove the machine from service repair and re inspect it After repair place a check in the R box Legend 16 Y yes acceptable N no remove from service R repaired B 4 Brake configuration Daily or every 8 hours A B 5 Drive hub oil Quarterly or every A B B 6 Ground control 250 hours override Semi annually or A B C B 7 Platform leveling every Sop B 8 Drive brakes Annually or A B C D every B 9 Drive speed 1000 hours stowed 0 8 10 Drive speed raised B 11 Alarm package B 12 Turntable rotation stop B
150. l 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 panel e Function manifold wiring Genie 22 Z 30 20N Z 30 20N RJ 2 34 22 2 34 22 Part No 139378 January 2015 3 Turn the key switch to ground controls and pull out the red Emergency Stop button to the on position at both the ground and platform controls 4 Raise the secondary boom until the mid pivot is approximately 10 feet 3 m off the ground 5 nspect the turntable center area for burnt chafed and pinched cables Lower the boom to the stowed position and turn the machine off 7 Inspect the following
151. l drift to remove the secondary machine boom rod end pivot pin 11 Open the ground controls side turntable A WARNING Crushing hazard The secondary boom lift cylinder may fall when 12 Remove the terminal strip cover retaining pin E fasteners Remove the cover supportes Ey iis 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 19 Remove the plastic plug In me bulkhead 0 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 js iod di 117 function manifold and slide the manifold to the DE ened side This will allow access to the hydraulic tank side barrel end pivot pin Genie 4 Part No 139378 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N 75 January 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 A WA
152. le switch until air stops coming out of the bleed valve Crushing hazard Keep hands A WARNING 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 2 Switch to either side and move and hold the jib w pl and boom rotate toggle switch to the right for i irene 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 January 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 i 5 4 Use a 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 level
153. llow 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 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 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 January 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 an
154. low 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 January 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 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 lower 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 3 mm below the bottom of the battery fill tube Do not overfil
155. lt Code Programmer Diagnostic Display Condition Possible Causes Solution Fault code LED is off or is on but not blinking COMMUNICATION ERROR Machine will not drive The key switch or Emergency Stop button s was cycled on and off faster than 5 seconds OR controller sensed an internal error during start up Push in the ground control red Emergency Stop button to the off position and wait for 5 seconds Pull out the ground control red Emergency Stop button to the on position If problem persists replace the motor controller Normal operation controller 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 96 Genie Z 30 20N Z 30 20N RJ 2 34 22 2 34 22 Part No 139378
156. lure to 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 Genie re engage the drive hubs could result in death or serious injury and property damage 36 Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N Part No 139378 January 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 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 AWARNING 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 9 1 09 7 0 11 20 gt 120 6 0 0 3 10 8 Bolt torque sequence Genie BRAND Z 3
157. machine Part No 139378 January 2015 Service Manual E 1 Test or 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 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 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
158. mum 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 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 January 2015 Checklist C Procedures 4 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 illustration 1 5 Carefully move the test weights to each remaining location on the platform Refer to Illustration 1 R
159. n 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 right 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 burn skin Loosen hydraulic pressure connections very slowly to allow 0 the oil pressure to dissipate 6 Remove the pin retaining fasteners from the gradually Do not allow oil to jib boom and leveling links to platform rotator squirt or spray pivot pins Do not remove the pins Genie 50 Z 30 20N Z 30 20N RJ 2 34 22 2 34 22 Part No 139378 January 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
160. nal 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 Part No 139378 2 30 20 Z 30 20N RJ Z 34 22 2 34 22 87 Service Manual January 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 Test a Coil 2 Connecta 100 resistor to the negative terminal of a known good 9V DC battery Connect the other end of the resistor to 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 P 5 z 1 100 9V 1 multimeter 2 9V DC battery 3 100 resistor 4 coil Note Dotted lines in illustrati
161. ntrol Box Switch Panel Wiring Diagram AS from serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 154 155 January 2015 Service Manual HE EI Platform Control Box Wiring Diagram AS CE from serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 Service Manual January 2015 __________ _____ ___ Platform Control Box Wiring Diagram AS CE from serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 B 0 D E F G H K L M
162. nually 9 Install the filter housing cap Whichever comes first 1 il that h illed duri 9 4 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 12 Turn the key switch to ground controls and pull out the red Emergency Stop button to Note Perform this procedure with the machine on position a firm level surface with the boom in the stowed 13 Move 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 Maintenance Procedure Grease the direction Turntable Bearing and Rotate Gear 14 Inspect the filter housing and related 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 2 34 22 Z 34 22N 39 Service Manual Checklist D Procedures
163. o 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 68 20 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 item H Solenoid valve N C 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
164. ocedure 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 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 January 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 end for support Raise 10 Place a rod through the upper secondary the primary boom using the overhead
165. 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 Z 34 22N 41 Part No 139378 7 7 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 1 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 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 13 squirt or spray 14 Bodily injury hazard Beware of A CAUTION hot oil Contact with hot oil may cause severe burns 15 6 Remove the hydra
166. olts 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 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 see 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 January 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
167. om serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 Service Manual i st January 2015 Ground Control Box Terminal Strip Wiring Diagram AS CE from serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 152 A B C D E F G H K L WIRES FROM CONNECTOR TO CONNECTOR M ISE SECONDARY TERMINAL BABE DESCRIPTION CIRCUIT amp 4 UP DOWN FEABH BEACON OFT 184 RD Ca2 1 KEYSWITCH POWER WIRES CIRCUIT FROM DESCRIPTION RD AWH TLT WH 184 4 POWER BK cus 0521 1614 82 JUNCTION BR CB2 BK FLASH BEACON 52 BR MH BR CRA GROUND BATGND WH J2 4 1624 64 JUNCTION 08 2 078 3 52 BR SP GROUND BATGND Sib ROTATE HT GSN RU GAIN 153 DRIVE ENABLE B WH BK SP 48 BRAKE RELEASE OR BK C47JRR C2B 8 TS 66 SP BD WH CRS RD WH MH RD WH SP p nm m 1848 60 JB ROTATE TET GRE 42 ORIRD CR1
168. on 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 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 20 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 January 2015 4 4 2 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 Rot
169. ons 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 2 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 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 Part No 139378 January 2015 Service Manual 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 aler
170. ons are Wheel width subject to change without notice or obligation 18 cm Genie Part No 139378 Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N 1 Service Manual January 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 0 6 mph1 km h40 ft 42 sec12 2 42 Boom raised or extended Drive speed maximum Stowed position 4 5 mph 7 2 km h 40 ft 6 0 sec 12 2 6 0 sec 0 6 mph1 km h40 ft 42 sec12 2 m 42 sec Boom raised or extended 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 secured 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 Jib boom rotate 180 17 to 21 seconds 13 to 17 seconds Jib boom down Primary boom up 18 to 22 seconds 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 P
171. ontain 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 adjust 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 F 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 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 al
172. oom 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 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 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 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 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 How to Bleed the Jib Boom Rotator No
173. oted elsewhere in this manual Class 10 9 Class 12 9 23 1 2 176 271 433 A74 718 908 1138 1260 e e e 50 1 555 773 867 108 4 122 149 176 27 298 433 474 650 718 908 1138 1260 1979 2223 uU m di 0 m d d Lo e w mis INS OO A ele INS mi Pan gt la o o eo 1 3 oe Hle r c 2 lt w m 2 lt r c w m ale Nm 6 2 2 46 7 81 110 108 147 0 202 274 269 365 525 3 715 0 762 583 791 778 1055 682 925 909 A A o N o Q e a gt o o Io gt Cio 60 22 gt 5 gt v Go 5 E m a 420 570 Gen
174. out 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 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 January 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 th
175. 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 properly attached to the overhead crane Genie BRAND Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N 67 Part No 139378 Service Manual January 2015 Secondary Boom Components ONCE QS 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 o 68 Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N Part No 139378 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
176. pleting 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 Y yes acceptable N 7 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 2015 Service Manual _________ __ __ This page intentionally left blank Genie BRAND Part No 139378 Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N 15 Service Manual January 2015 Maintenance Inspection Report 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 4 30 service D 2 Free whee
177. raulic 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 30 20N RJ 2 34 22 Z 34 22N 69 Part No 139378 Service Manual January 2015 Secondary Boom Components 14 15 16 17 18 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 AWARNING Bodily injury hazard Spraying 19 20 21 70 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 f
178. 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 2 34 22 Part No 139378 January 2015 Service Manual B 1 Inspect 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 c
179. rimary 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 Platform level down 14 to 19 seconds 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 January 2015 Service Manual Hydraulic Specifications 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
180. rker 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 v Genie Z 30 20N Z 30 20N RJ 2 34 22 2 34 22 E Illustration 1 1 hex nut 2 reference mark 3 body hex fitting Part No 139378 2015 Service Manual ____ _ _ ___ 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 S Illustration 2 1 body hex fitting 2 reference mark 3 second mark 4 Tighten the 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 Service Manual January 2015 Specifications SAE FASTENER TORQUE CHART This chart is to be used as a guide only unless noted elsewhere in this manual A574 H
181. rly dispose of old oil or Indicates a potentially hazardous 2 other fluids Use an approved container situation which if not avoided Please be environmentally safe may result in property damage Be sure that your workshop or work area Be sure to wear protective eye wear and is properly ventilated and well lit other protective clothing if the situation warrants it Be aware of potential crushing hazards Bl such as moving parts free swinging or unsecured components when lifting or placing loads Always wear approved steel toed shoes Genie BRAND Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N vii Part No 139378 January 2015 22 42 2 24 O Table of Contents Introduction hiienipibDnm ii Important Information ade it ii Find a Manual for this ii 7 iii Serial Number Legend ed et teat b e na V Section 1 CIA fte vi General Safety da ad eee RR a E au aeu a vi Section 2 5 pner cratera ax ER rta LEER adju d 1 Machine eene eene 1 Performance 2 Hydraulic Specification sensasie Dena donee 3 Hydraulic Component Specifications 2
182. rom 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 Remove the pin retaining fasteners from the upper pivot to upper secondary compression arm pivot pins Use a soft metal drift to remove the pins 23 Swing the compression arms down and out of the way Secure them from moving 24 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 25 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 AWARNING 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 Place the entire assembly onto a structure capable of supporting it 27 Remove the pin retaining fasteners from the upper secondary compression arm pivot pins Do not remove the pins 28 Position a lifting strap from an overhead crane at the center of the control box side upper secondary compression arm hA Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N Part No 139378 AWAR
183. s 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 2 30 20 Z 30 20N RJ 2 34 22 Z 34 22N Part No 139378 2015 Service Manual Introduction Serial Number Legend Genie n A TEREX BRAND Model Z 30 20N 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 lt Maximum number of platfrm occupants X E Maximum allowable side force XXX Ib XXX N Maximum allowable inclination of the chassis 0 Maximum wind speed XX mph XX m s Maximum platform height XX ft XX m Z 30 20N Maximum platform reach XX ft 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 5 F3 Watertown SD 57201 USA Z 34 22N 1 Model 2 Model year 3 Sequence number 4 S
184. setting 7 Remove the pressure gauge Genie 82 Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N Part No 139378 January 2015 wi 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 s
185. sion 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 2 34 22 2 34 22 Part No 139378 2015 Service Manual Checklist B Procedures B 9 5 Bring the machine to top drive speed before reaching the start line Begin timing when your Test the Drive Speed Stowed reference point on the machine crosses the Position start line 6 Continue at full speed and note the time when the machine reference point crosses the finish line Refer to Specifications Performance Genie specifications require that this procedure be Specifications performed every 250 hours
186. sition 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 1 Brake circuit 13 Solenoid valve N C poppet M Brake circuit 20 25 ft lbs 27 34 Nm 14 Orifice 0 045 inch 1 14 mm N Brake circuit 78 Genie Z 30 20N Z 30 20N RJ 2 34 22 2 34 22 Part No 139378 Manifolds January 2015 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N 79 Part No 139378 Service Manual January 2015 Manifolds Function Manifold Components continued Index Schematic Description item Function Torque 15 Orifice 0 045 inch 1 14 mm 0 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
187. t o m 5 2 4 1 9 10 1 14 16 2 3 17 20 5 R42BAT OR RD DRIVE CONTACTOR UGA SEPEX CONTROLLER CR24 1 M B F2 18 B DIODE LIII SCHEMATIC 5 CONTROLLER ra o BATTERY INDICATOR LED R42BAT RD 6 1 LED IS 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 15 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 BATTERY AND MAIN SUPPLY CONTACT OPEN n 5 T m n c tr m o ars ES34BEAB o 558 24 23 22 21 20 19 18 17 16 15 14 13 12 11 8 17 615 4 31211 8 SEPEX CONTROLLER WIRING DIAGRAM Genie ATEREX BRAND 112 Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N Part No 139378 P22L8BK 6101847 0 2 5 TB15 814 B 9 9 nm E 8 5 g g g C40LS OR C
188. t 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 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 Gen BRAND Checklist B Procedures Turn the key switch to platform control At the platform controls pull out the red Emergency Stop button to the on position Result The flashing beacon should be on and flashing 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 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
189. te This procedure will require two people A WARNING Crushing hazard The jib boom 1 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 Genie 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 56 Z 30 20N Z 30 20N RJ 2 34 22 2 34 22 Part No 139378 January 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 valve but do not remove it 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 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 52 8 Rotate the jib boom to the right and continue holding the platform rotate togg
190. tform overload indicator light and alarm responds Genie 52 Z 30 20N Z 30 20N RJ 2 34 22 2 34 22 Part No 139378 2015 Service Manual ______ _ ___ __ ___ _ __ Platform Components 9 Testall machine functions from the platform controls Result All platform control functions should not operate 10 Turn the key 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 Test all 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 January 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 eq
191. the bottom bleed screw on the rotator but do not remove it 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 6 Move the function enable toggle switch to either side and hold 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
192. 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 Service Manual January 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 DANGER Indicates a imminently hazardous situation which if not avoided will result in death or serious injury A WARNING 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 may result in property damage Indicates that a specific result is expected after performing a series of steps W Indicates that an incorrect result has occurred after performing a series of steps 1 1 1 12 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N Part No 139378 January 2015 Service Manual Scheduled
193. the turntable rotation lock Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N 45 Part No 139378 Service Manual January 2015 mna et 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 Then to re assemble perform the disassembly steps in reverse order Symbols Legend Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death DANGER Indicates a imminently hazardous situation which if not avoided will result in death or serious injury A WARNING 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 may result in property damage Indicates that a specific result is expected after performing a series of steps W Indicates that an incorrect result has occurred after performing a series of steps
194. 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 3 Tag and 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 Use a 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 Gen
195. ually 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 hazard 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 January 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 AWARNING 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 Em 18 Remove the hose clamp under the lower pressure 10i CISSIpa 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 Bodily injury hazard Beware of access holes in the bulkheads one on each CAUTION hot oil Contact with hot oil may side 20 Remove the retaining fastener from the 10 Remove the hydraulic tank mounting secondary boom lift cylinder rod end pivot pin fasteners Remove the hydraulic tank from the 21 Use a soft meta
196. uals 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 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 20N RJ 2 34 22 Z 34 22N 17 Part No 139378 Service Manual January 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 be
197. uid Properties ISO Grade 46 Viscosity index 154 Kinematic Viscosity cSt 200 F 100 C 8 0 cSt 104 F 40 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 46 cSt 0 F 18 C 1300 Flash point None Pour point 81 F 63 C Maximum continuous operating 189 F 87 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 Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice or obligation Genie 4 Z 30 20N 2 30 20 RJ 2 34 22 Z 34 22N Part No 139378 2015 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 305 SAENo 6 14 ft lbs 19 Nm Flow rate 602800 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 I9 AT EDSA SS AM 1 7 bar bypass SAE N
198. uipped 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 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 T
199. ulic 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 January 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 tank on the machine Install the hydraulic tank mounting fasteners and torque them to 8 ft lbs 10 8 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 January 2015 Service Manual E 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 th
200. witch 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 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 presento 7 Remove the pressure gauge Genie ____ Part No 139378 Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N 83 Service Manual January 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
201. y 2015 Hydraulic Schematic A B C D E F G H JIB BOOM 1 JIB BOOM ROTATE Z30NRJ PLATFORM ROTATE Poe SS GOUNTERBALANCE VAL
202. y 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 connections 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 Supportand 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 Use 8 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 Part No 139378 Z 30 20N Z 30 20N RJ 2 34 22 Z 34 22N 55 Service Manual January 2015 Jib Boom Components 3 3 Jib B

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