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Service Manual

1. ROTATE MANIFOLD EXT RET oe sup PR2 ____ 1 3000 PSI 207 bar 3300 PSI 1 51 228 bar 3 1 2 222 0 par Pe 3 t t x A X I J cun PLATFORM LEVEL 1 4 Limi SLAVE CYLINDER i 4 JIB MANIFOLD eee ee i eS eS SECONDARY PRIMARY EXTENSION CYLINDER CYLINDER CYLINDER STEER 13 FT ost mm M CYLINDER S 5 T 9 y i w 9 TURNTABLE ROTATE x i BRAKES 1 Lil 4 11 WORM DRIVE 3000 PSI EM 207 bar 4 5 9 CU IN REV MASTER gece REN E mt 4 4 r e CYLINDER EE NE ET bd 9 mE OME Me om HC 6 3000 PSI 207 bar 4 oe ae rd 151 3000 PSI 2500 PSI E 207 bar 172 bar NO 3 1 eoo e EET ET S EROR TO PP AU
2. JE i i EE RE i E 55552 TAO SZ 5 a aao 2 sos amp BEES 5 E 2 6 a oz i 5 i zi 1 36 lt 1 lic i i i Bi PRIMARY Tod UP 2 RED BOOM UP c PRIMARY BOOM 3 RED BLK 2 G orman E DOWN 7 BOOM DOWN RED RED BLK3 ord SECONDARY oo UP BLUMO bi BOOM UP x SECONDARY Boom BLU BLK 11 SECONDARY Dani DOWN BOOM DOWN ME a3 DECENT ALARM UP BLUS 222 X SECONDARY BooM BLU BLK 3 DOWN TURNTABLE RIGHI WHT BLK 5 n ROTATE RIGHT TURNTABLE S SOME 1 1 TURNTABLE 1 FE dd ROTATE LEFT RIGHT WHT BLK 3 TURNTABLE ROTATE WHT 3 a IPIE LEFT m P dn B a gt Og p 658 5 58 uc LE uc B EUR VEL WHT 23 D gt WHT 2 e EB 28 5 5
3. PR 1 3000 PSI 207 bar SI 153 Oe pa Pro 3 i i I B I NXE TS C AXES i gt PLATFORM LEVEL c 14 nin SLAVE CYLINDER x i 4 JIB MANIFOLD UO ME See SSS i d EXTENSION CYLINDER SECONDARY CYLINDER PRIMARY CYLINDER 0 032 i mE 0 81 mm TEER CYLINDER BRAKES SIEHE ur li gt 5 a TURNTABLE ROTATE i EP pe i WORM DRIVE 3000 207 bar Regen added after 4 5 1 serial numbers T oN 234 3216 MASTER rt L t 0t DN CYLINDER O 090 orifice added J B n L4 after serial numbers pese 4 al SF Z34N 4017 6 xX a ct 3000 PSI 20008 3 3000 PSI 172 bar NO 207 bar 20 81 COM C 1 541 3 1 aa ae sn
4. m N r ul x 8 aii 5 BRN C7P 3 BATGND BRN C7B 3 BATGND BRN GY C4P 1 C13DEL BURD C13DEL BURD C84 wHs 8 S BRN S C82 4 APA 8 5 12 _C12FTS BLWH_ C3B 12 CI2FTS BLWH BK5 5 C8 1 Ts 2 C4P 4 160 OR RD C4B 4 C16DE OR RD i OR RD IE eH v 9 y RD WH 4 28 g un c2 R48BRK RD WH 25 e eoe eaS E oe 3 Le m z Suga is 22 sober 5 252 5 lt PS1 1 x E Bb 10 C36SCC BL C1B 10 BL 4 M 5 1 11 C37SCW BUBK 1 11 BL BK 5 ie epe 1 Z z 500 c al x 5 gt E22 L gt EVELLE Y y a Eg ap WH BK fe d zs t aW Ajo 2 8 88 e NUT m C27AUX RD C1B 1 RD AUX o I FEE x E S 2 5 8 5 Fa le Se 2 E OR RD E 538 RD m 8 amp 5 g z ZEF 4 1 8 B 5 D B a orm L4 B l O 1 f a Vv 1 ii i 7 4 C19LPE GR WH I 191 GR WH m 1
5. cae TERMINAL BASE TB DESCRIPTION CIRCUIT WIRES FROM CONNECTOR TO CONNECTOR LS4 SECONDARY RD WH FLASH BEACON 134 RD C32 1 KEYSWITCH POWER C134PWR ES E Em 1 UP DOWN 2 RD WH TILT WH C7B 2 134 RD A6 CE OPTION RD KSI 4 KEYSWITCH POWER C134PWR C8 BR CB2 BK FLASH BEACON OPT 52 BR MH BR CR4 GROUND BATGND wi 32 ene Dion ES2LS4 JUNCTION BR C amp 2 BR C7B 3 52 BR BR SP GROUND BATGND H es eset Petree JUNCTION LS3 DRIVE ENABLE RD WH CRS 4 ROWH MH RDMWH SP BRAKE RELEASE C48BRK GREK CD oe DOWN GR C43JU C2B 5 SP JIB UP OR RD CR1 OR RD C2B 4 42 OR RD C49 10 OR RD L3 SWITCHED 48V R42BAT C11 Buek ieD C1B 11 37 BLBK MH STEER RIGHT C378CW on MES ose en DFE EMIT SPERI WH RD C1B 6 CH JOYSTICK POT LOW 4 190 BL C1B 10 36 BL MH STEER LEFT C36SCC LS2 PRIMARY WH BK C31REV C1B 5 REVERSE UP DOWN RD CR3 RD C18 1 27 RD SP AUXILIARY PUMP SELECT C27AUX v E ae 2 10 2 BK C23 4 22 BK SP BK CR4 424V TO PLATFORM P22BAT EUER SWIREROT ei 0 TB36 TB37 GR WH CR3 19 GR WH MH 4 LIFT PUMP C19LPE 18 8 en 28 4 LS1 PRIMARY 5 SHARE 2 ARWSP ao ni C18PRR E A ROTAT
6. r 1 1 2 51 LOAD SENSE OPTION LOAD SENSE OPTION SEE DETAIL a BLK FS 1 WHT FS NG BLK 2 BLK FS J wire Nt WHT FS WHT Ly X REDIBLK NO QQJBEDIWHT UE EI eee Season ame a 3 ORG RED 1 qu E 8 E tia Ps RED 3 3 HORN m PLT BLK 22 CL n 2 10 P1 KS e Z A E TB22 5 ALARM e le e d 1 C3 GND RED RED RED WHT 30 WHT 1 WHT 1 WHT BLK 31 Tt WHT BLK 1 WHT BLK 1 RED WHT 29 il RED WHT 1 RED WHT 1 i WHT RED 32 WHT RED 1 WHT RED 1 ORG 40 T540 BLK 8 9 TB3 me rr TTE tcI RON te ORG RED CR2 1 t H aya 2 BLU WHT 12 4 91154 o 9 ot E 3 RED j 8 s 85 cRs p z 2 a AP2 10 FI P lt 8 m i 2 2 gt E TS55 RED s RED 500A 86 4 9 9 5 5 I 3 1 t bl ET 4 N N 448V ERI TB50 9 FUNCTION nae pate ENABLE lt a 4 TB28 30 cgo 86 F2 2 MES 5 ur 9 RED 5 100A a g I 4 v nok x 87 85 8 MI E en 62 E i 86 30 zi
7. First Edition Third Printing Electrical Schematic 7 34 22 after serial number 4799 7 34 22 after serial number 5619 Section 6 Schematics i 1 i Ve e BE Z z 2182 img amp mc m o Ss o 8 5 8 amp S z amp c 4 SO o o 1 1 i i 1 1 1 i 1 i 1 1 i 1 1 i 1 1 i 1 1 i 1 i i 1 i 1 1 i 1 i 1 1 i 1 1 i i 1 i i 1 1 1 i 1 1 i 1 1 1 i 1 i i 1 1 1 i 1 1 i 1 1 1 1 i C2P 4 4 R42BATOR RD 2 4 OR RD M S e 8 58 5 i 61 5 5 i 88 Ew C3P 8 C3BAT RD WH 38 3 i 3e BRN 48V POWER ge RELAY CR2 wpe i 5 oe BAN 48V POWER g ts RELAY CR1 BN E ey A FLASHING BEACON z NDA OPTION ba I x 55 1 Far 2 s C28TTARDIBK CIB2
8. RED BLK WHT WHT FS REDAWHT BRN WHT FS TS15 TS12 TS10 y o BP1 TS7 TS11 TS8 EAD RED COO GRN TS9 TS13 amp 9 49 Lt O O 12 i 2 3 4 5 6 7 8 9 10 OO V STS NC NC TS1 9 ia P3 P2 DP1 6 6 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 6 Schematics TANK SIDE BATTERY PACK PRIMARY LIFT PUMP PR3 PRIMARY LIFT PUMP CONTACTOR 400A CONTACTOR Power Cable Diagram Z 34 22 before serial number 3578 Z 34 22N before serial number 4261 AMMETER BLK WHT V AC BATTERY CHARGER e9 01 LHM o1 na DRIVE LEFT SIDE DRIVE MOTOR AMMETER BLK 10 Ga WHT 10 i i i SIDE E BATTERY PACK BATTERY CHARGER PRIMARY LIFT PUMP e9 01 LHM 901 PR2 PRIMARY LIFT PUMP
9. CHART 30 Continued from the previous page Press down the foot switch and move the drive controller in either direction and check voltage at TB48 24V Insert a jumper wire between TB48 and TB19 Press down the foot switch and move the drive controller in either direction Does the power unit turn on no Press down the foot switch and move the drive controller in either direction Check voltage on the red wht wires on the brake release valve coils items G and 24V Remove the brake release valve coil and clean the coil contact es rings on both ends of the coil Then install the coil onto the valve cartridge Drive the machine Do the brakes release Continued on the next page First Edition Third Printing Repair open in red wht 48 wire from terminal 87 5 to TB48 OR replace diode Remove the pressure switch plug and place a jumper between terminals 1 and 2 on the plug Press down the foot switch and move the drive controller in either direction Does the power unit turn on es Replace the pressure switch Repair open in red wht 48 wire from TB48 through red wht wire circuit to pressure switch then grn wht 19 wire with diode to TB19 OR replace the diode Repair open in red wht wires from TB48 to the brake release valve coils items G and K Drive and
10. oe E gt G3 ji M G Le Ld o Oj Brake Drive a notused b notused terminal X d terminal ground e terminal f terminal A proportional output g thresholdadjustable trimpot h max out adjustable trimpot 5 Disconnect the white red wire from the A terminal on the brake controller printed circuit board 6 PLATFORM CONTROLS Connect the black lead from an ammeter to the white red wire that was removed from the brake circuit board Connect the red lead to the A terminal on the brake controller printed circuit board Locate the drive controller printed circuit board m n 2 S S S e SS 2 SS e SS LR Brake Drive a max out adjustable trimpot b threshold adjustable trimpot terminal A proportional output d terminal ground f terminal blank g notused h terminal activates max out range i lo range adjustable trimpot Connect the red lead from a volt meter to the A terminal on the drive controller printed circuit board Connect the black lead to ground Part No 36540 Genie Z 34 22 amp Genie Z 34 22N TOW OM X OI ee A eee ae eae A eae
11. CHART 19 Disconnect the org blk Oor Continued from the wire from the platform infinite previous page level down directional ohms Replace platform level valve coil Test the down directional valve resistance of the valve coil coil See Repair Section Exchange the platform level and turntable ae rotate directional valves items AL and AJ or items BL and BJ or items CA and CT Activate the platform level DOWN function function inoperative function courterbelance bates Replace defective valves items AN and counterbalance valve AO or items BN and BO or items CB adn CC Activate the platform level DOWN function function inoperative Install a 0 to 5000 PSI Check for mechanical 345 bar pressure restrictions keeping the gauge at the quick platform level down disconnect coupling on function from operating the function manifold OR repair or replace Activate the platform the slave cylinder or level down function and slave cylinder check the pressure counterbalance valves OR consult Genie Industries Service Department less than 3200 PSI Test the master cylinder refer to Chart 16 OR repair or replace the slave cylinder counterbalance valves OR function manifold could have an internal defect Consult Genie Industries Service Department Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 5 79 Section 5 Troubleshooting Flow Charts First Edition Third Printi
12. 1 OP FS1 LOAD SENSE OPTION LOAD SENSE OPTION SEE DETAIL 122 BLK FS WHT FS 1 BLK FS J i WHT FS WHT iN m RED BLK 2 hice Mate Me aan fen eee ena aaa re ORG RED 1 m 8 F 2 LOAD SENSE RED E e m xl KS1 PLT BLK 22 TILT p 2 ALARM ev ais SP e RED RED ORG RED CR20 RED WHT 30 ESQ WHT 1 WHT 1 WHT BLK 31 TB31 WHT BLK 1 WHT BLK 1 I RED WHT 29 RED WHT 1 WHT RED 32 WHT RED 1 ORG 40 Lu ORG RED CR2 t BLUWHT 12 4 1 9 9 E 8 2 REP m 9 8 g 5 ve 500A g E S ES E RED RED 48V ud 3 L 5 E PRI S 8 B 1828 48V pes earn 1 I i pE peer Bici pee rey ro eee ae pe Ei S Tce A 4 TB28 In B n RED n gt 5 8 5 4 o 3 35 8 me RI E Uy 2 Ji 9 A et Le o i 9 gt 9 o x i ILL 2 amp 8i z 2 9 2 3 5 m m 3 gt gt T m lt 2 im ma 2 2 5 z m m m Ut 83 S 5 B 8 B ES 3 i 3 2 D m x 1 9 3 3 9 9 130 d 2 16 14 3 20 x 5 17 BLK 5 S B8 6 g STATUS LED 2 SEPEX CONTROLLER Ls1 2 BL 1 1 B F2 091 x92 E bi PR3 PR2 1 35 52 m S 2
13. 5 76 Platform Rotate Left Function Inoperative 5 80 Platform Rotate Right Function Inoperative 5 84 Jib Boom Up Function Inoperative 5 88 Jib Boom Down Function Inoperative 5 91 Steer Left Function Inoperative Z 34 22 before serial number 1734 and Z 34 22N before serial number 2227 sse 5 94 Steer Left Function Inoperative Z 34 22 after serial number 1733 and Z 34 22N after serial number 2226 2 2 20 2 40 1 000 5 95 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing EET TABLE OF CONTENTS Section Five Troubleshooting Flow Charts continued 26 27 28 28A 29A 29B 29C Steer Right Function Inoperative Z 34 22 before serial number 1734 and Z 34 22N before serial number 2227 sse 5 97 Steer Right Function Inoperative Z 34 22 after serial number 1733 and Z 34 22N after serial number 2226 00 2022 0 0 000 5 98 All Drive Functions Inoperative All Other Functions Operate Normally Z 34 22 before serial number 1734 and Z 34 22N before serial number 2227 5 100 Brake Function Inoperative Z 34 22 before serial number 1734 and Z 34 22N before serial number 2227 sss 5 106 A
14. ORG 3 ORG BLK 3 DOWN EXTEND f Fa BLK 7 i PRIMARY BOOM EXTEND PRIMARY BOOM 8 1 1 r PRIMARY BOOM RETRACT RETRACT BLK 3 BLK WHT 3 i i i al a a i i am e I TE X I x i 3 a a 8 FIG a Glar gt gt 1 2 Zl dala ba ola S 5 6 14 Genie 7 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 6 Schematics Electrical Schematic 7 34 22 before serial number 153 7 34 22 before serial number 304 First Edition Third Printing C 7 34 22 from serial number 153 to 1733 7 34 22 from serial number 304 to 2226 Electrical Schematic Section 6 Schematics
15. 4 RED WHT WHT RED RED 1 NCOW NO TS8 zi m P3 P2 NC O WHT RED 32 1 ORG BLK 41 1 RED WHT 3 ORG 40 1 BLU BLK 37 1 RED WHT 29 1 BLU 36 1 BRN JIB RED TILT ALARM WHT 2 BLK FS BLK 2 RED 27 1 WHT JIB BLK JIB Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 6 36 First Edition Third Printing Section 6 Schematics Platform Control Box Wiring Diagram Z 34 22 from serial number 1734 to 1834 Z 34 22N from serial number 2227 to 2448 N M L K J G F E D 1 7117 7773 WHT ORG BLK X 1915 2 TS1 Q RED U J
16. BLU 10 SECONDARY BOOM UP m BLU BLK 11 SECONDARY 5 4 BOOM DOWN 11 4 ALARM OPTION UP BLU 3 i t SECONDARY BOOM DOWN 1 RED BLK 3 1 2 DESCENT J 4 BLU BLK 3 RIGHT M WHT BLK 5 h 1 TURNTABLE ROTATE LEFT TURNTABLE ROTATE RIGHT T WHT 4 TURNTABLE ROTATE LEFT WHT BLK 3 WHT 3 RED BLU WHT 12 ORG RED 1 WHT BLK 1 WHT RED 1 RED WHT 1 RED RED RED BRN BRN 6 18 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 6 Schematics Electrical Schematic 7 34 22 from serial number 1734 to 1834 Z 34 22N from serial number 2227 to 2447 Section 6 Schematics Electrical Schematic Z 34 22 from serial number 1835 to 2060 Z 34 22N from serial number 2448 to 2870 C A B First Edition Third Printing
17. EI I E c la z ela 5 zig E 3 8 IEEE a 3 o 2 312 o 2 gi 5686 2 Ojoo r 1 1 1 1 1 1 1 1 1 1 1 1 i 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 i 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 i 1 1 1 1 i 1 1 1 1 1 1 1 1 1 i 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 i 1 1 1 1 1 1 1 1 1 1 1 1 1 1 T 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 i 1 1 1 1 1 2 4 R42BATOR RD 2 4 OR RD NA g e a bid 9 HP T i elu i C3P 8 C3BAT RD WH C3B 3 1 S co 1 48 ale zi s RELAY CR2 gu 1 HE 2 i BRN yt 48V POWER S 1 RELAY i ate ee 1 5 1 FLASHING BEACON P OPTION 2 5 i 5 1 2 n 2 C28TTARD BK C1B 2 RD BK WH i A et 2 X P23BAT WH C7B 2 gi RD RD BIS SPAN TILT SENSOR 9 ter l 5 lt iB B al 5 amp BE E E f 5 Sg BASE CONTROL z 1 B BOX GROUND ld ford g e art o 9 C9HRN BK RD C3B 9
18. 6 0220 4 25 B 20 Replace the Hydraulic Tank Return 2 0 4 26 C 1 Check the Primary Boom Wear 4 28 C 2 Check the Turntable Rotation Bearing Bolts 4 28 3 Checkthe Free wheel Configuration 4 30 C 4 Grease the Turntable Rotation Bearing and Worm Drive 4 31 C 5 Replace the Drive Hub Oil 2 2024000 0 0 4 31 C 6 Bleed the Platform Rotator 4 32 D 1 Testor Replace the Hydraulic 2 2400 0 000 4 33 0 2 Grease the Steer Axle Wheel Bearings 2WD 4 35 Section Five Troubleshooting Flow Charts D EE 5 1 Fault Code Chart Z 34 22 after serial number 1733 and Z 34 22N after serial number 2226 5 3 1 All Functions Will Not 5 7 2 Lift Pump Motor Will 5 10 3 Auxiliary Pump Motor Will Not Operate 2 5 17 4 All Functions Inoperative Power Unit Starts and 5 20 5 All Lift and Steer Functions Inoperative Drive Function Operational 5 21 6 Ground Controls Inoperative Platform Controls Operate Normally 5 25 Part No 36540 Genie Z 34 22 amp Genie Z 34 22N ix F
19. AUXILIARY PRIMARY P1 et BRAKE Lee 2 Pa 2 TE gel 02 2 ped RET 4 05 GPM 21 3200 PSI ral Es i in id 221 bar tmm SG oe 7 0 5 GS AT E oO WIE HW o s C Ln t zaas ec b s 1 1600 PSI 1600 PSI 2800 51 23403766 gea e om E E b Ls 110 bar 110 bar 193 3000 1100 PSI cr A cP 207 bar 76 bar E E Ju e T X a 1 y T4 0 045 inch HEX PLURA HHX Lr DA nan 6 Dum 100 5 f X 17 0 8 GPM 15GPM 8 i 3 L min 7 i X i i 5 7 L min PCR HYDRAULIC TANK otenn CS 089 mm x Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 6 45 First Edition Third Printing Section 6 Schematics m Hydraulic Schematic 7 34 22 after serial number 2900 Z 34 22N after serial number 3532 First Edition Third Printing Section 7 Repair Procedures Observe and Obey Repair procedures shall be completed by a person trained and qualified on the repair of this machine Immediately tag and remove from service damaged or malfunctioning machine Repair any machine damage o
20. 19 Press down the foot Repair open in grn wht switch and move the wire circuit through platform level toggle boom function toggle Switch in the DOWN Switches to the red wire direction Check the on the boom function voltage at the red wire speed controller on the boom function speed controller Continued from the previous page Press down the foot Repair open in ground switch and move the wire circuit from the platform level toggle boom function speed switch in the DOWN controller to ground OR direction Check the replace the boom voltage at the blk red function speed wire on the boom controller function speed controller Repair open in blk red wire from the boom function speed controller to TB6 Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 5 77 Section 5 Troubleshooting Flow Charts First Edition Third Printing EE e EEE CHART 19 Continued from page 76 Turn key switch to ground controls and pull both Emergency Stop buttons out to the ON position 2 34 22 before serial number 153 and Z34 22N before serial number 304 Move platform level toggle switch in the DOWN direction and check voltage on the org 15 wire on the platform level up directional valve coil item AL Z 34 22 after serial number 152 and Z34 22N after serial number 303 Hold the function enable toggle switch to either side and move platform level toggle switch in the DOWN directio
21. Genie Z 34 22 amp Genie Z 34 22N Part No 36540 H J K L BLK TILT AL GRN YEL 2 51 GRN YEL CR2 GRN YEL TB50 GRN YEL TB51 GR YL PUMP 50 GRN YEL S P GRN YEL LS3 BLK LS1 BLK LS2 49 BLU WHT MH BLU WHT 1 48 RED B R V RED S P AL 47 RD WT TB46 OR B TB41 RD WT TB29 46 RD WT TB47 RD WT S P GRN BLK 1 44 GR BK S P GR BK D A GRN 1 43 GRN S P OG RD POW ORG RED 1 42 ORG BLK PR1 ORG BLK 1 41 ORG BLK TB47 WHT LS2 ORG 1 40 BLU BLK S V BLU BLK 1 37 19 gt BLU STEER V BLU 1 36 BU TB19 gt WT RD BK F C WHT RED 1 32 WT BK PR2 WHT BLK 1 31 WHT PR2 WHT 1 30 RD WT B V R W 1 29 R W IB46 4 WHT T AL RED BLK 1 28 RED CR2 RED 1 27 RED S P WHT LS1 RED TILT AL 23 WT S P WHT 2 22 BLK S P BLK 2 RED POWER 20 RED S P gt GN WT P S 19 GR WT TB36 amp 37 GRN WHT CR2 GRN WHT 3 19 GR WT S P GRN BLK 3 18 GR BK S P GRN 3 17 GRN S P ORG RED 3 16 RED LS3 ORG BLK 4 ORG BLK 3 15 OG BK S P ORG 4 ORG 3 14 ORG S P BLU RED 3 13 WHT LS3 BLU WHT 3 12 RED S P H M BLK LS3 BLU BLK 4 BLU BLK 3 11 BU BK S P BU BK D A gt H BLU 4 BLU 3 10 BLU S P BLK RED 3 9 BK RD CR1 BLK WHT 4 BLK WHT 3 8 BKWT S P BLK 4 BLK 3 7 BLK S P W R 4 WHT RED 3 6 WI RDSP WHT BLK 4 WHT BLK 3 5 WT EK S P W
22. 1205 205 1 Motor controller Sepex 48V 500 amp 56012 Curtis Instruments 1244 5502 1 Contact 20732 ise Telemecanique ZB2 BE102 isse 4 lae Gontact i 45081 5 Telemecanique ZB2 BE101 1 Relay 180 19550 Curtis Instruments SW180 24DCCWAA 1 PR2 iuh Relay 180 amp 56434 Curtis Instruments SW180L 24DCCW 26 1 Relay 80 amp 19549 Curtis Instruments SW80 24DCCW 6 1 TS1 TS51 Toggle switch DPST 2 position momentary 13480 Microswitch Control Inc ONT 1 8 2 eee eae Toggle switch DPST 2 position maintained 27378 iun Microswitch Control Inc ONT 18 cete 1 TS7 TS13 and TS57 TS63 Toggle switch DPDT position momentary 16397 e Microswitch Control Inc ENTIT iue 14 TS2 TS6 TS15 TS52 TS55 TS56 Toggle switch SPDT position momentary 13037 3 Microswitch Control Inc TNT T 7 iui 6 TS4 ined Toggle switch DPDT position maintained 13038 Microswitch Control Inc A
23. LIFT PUMP AUXILIARY LIFT PUMP BLK 2 PR3 AUXILIARY LIFT PUMP 3 DIODES PR2 PRIMARY CONTACTOR LIFT PUMP CONTACTOR CURTIS MOTOR CONTROLLER NOTES 1 WIRE GAUGE NOTED IN PARENTHESES AFTER WIRE COLOR RED 10 RED 10 a DO NOT ROUTE POWER CABLES ACROSS FRONT OF THE MOTOR CONTROLLER DOING SO CAN AFFECT INTERNAL CURRENT SENSORS CAUSING REDUCED MOTOR PERFORMANCE BLK 2 dh 1 A1 Fi BLK 2 e RIGHT SIDE DRIVR MOTOR LEFT SIDE DRIVE MOTOR BLK 2 Fi RED 10 6 8 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 6 Schematics Abbreviations Legend LABEL DESCRIPTION PER Und Alarm BP Lessius Anderson Plug 202 Battery charge indicator option BP once Boom function speed controller Circuit breaker CR esed Control relay DE erect Drive enable Drive proportional controller FB uice Flashing beacon ES Foot switch Hour meter Le Brake release receptacle IK neues Key switch Light or LED Limit switch Low voltage indicator o
24. We EE 3 2 EE 3 2 Table C i indie etal eee asd ie e et ede eed ttt 3 4 gp 3 4 Maintenance Inspection 3 5 Scheduled Maintenance Procedures Introduction gea die c tede 4 1 A 1 Inspect the Operator s and Safety 4 2 2 Inspect the Decals and 4 2 Inspect for Damage and Loose or Missing Parts 4 3 4 Check the Hydraulic Oil Level 4 3 Part No 36540 Genie 7 34 22 amp Genie Z 34 22N vii First Edition Third Printing TABLE OF CONTENTS Section Four Scheduled Maintenance Procedures continued 5 A 6 A 7 A 8 A 9 A 10 A 11 B 1 B 2 B 3 B 4 B 5 B 6 B 7 B 8 B 9 B 10 B 11 B 12 B 13 B 14 B 15 B 16 Check for Hydraulic 4 22 222 0 4 4 Test the Platform and Ground 4 5 Test the Auxiliary Power Operation 4 7 Test the Tit Sensor e dh te tne dase RE HE MER aA 4 8 Test the Limit nnn nnns 4 8 Test the Lift Drive Select Switch if equipped 4 11 Perform 30 Day 50
25. S8 BE E 8 T P Om i 1 a Pies j i 4 2 a z Fe A2 2 ET fi 1 ALL LIMIT SWITCHES WITH BOOM IN STOWED POSITION EXCEPT AS NOTED 1 7 9 pra i a 00000 lt 2 SWITCH SHOWN WITH BOOM EXTENDED i S 4 00000 amp REDUNDANT COIL SUPPRESION DIODE FOR 1 IS INSIDE CONTROLLER BETWEEN J1 9 AND J1 17 m m NOTE DIODE INSTALLED AFTER SERIAL NUMBER 3819 Je lip 1 1 1 F2 m ll 1 PUMP i 5 LEFT MOTOR RIGHT MOTOR RA 3 eee dl i 2 GROUND g t GND BLK BLK BRN GND AP1 BRN 8 BLK 24V PR2 1417 m 2 5 2 2 gt D x Hd9uvHO Aava Od A8r HOLOVLNOO 6 21 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 NHOH NHOH NOLLdO NOOV38 SNIHSV 1H HOSN3S DL H3MOd Od A8 H3MOd Od Section 6 Schematics Electrical Schematic Z 34 22 from serial number 2061 to 3577 Z 34 22N from serial number 2871 to 4260 First Edition Third Printing BRN 2 WHT 5 21 22 BLU RED 3 TB13 BRN 5 DRIVE ENABLE LED 7153 BLU WHT 3 BLK 5 RED 5 DRIVE ENABLE LIMIT SWITCH TB12 14 13 ORG RED 3 Switch shown with boom rotated past tt TB16 either non steer whee
26. Fill with Dexron equivalent hydraulic fluid Replace the pump coupling Check the hydraulic fluid level Check for a positive no good connection between the electric motor and the pump by removing the pump from the motor but leave all hoses connected Visually check coupling connection no good Test the hydraulic pump See Repair section Replace the pump Consult Genie Industries Service Department Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 5 Troubleshooting Flow Charts All Lift and Steer Functions Inoperative Drive Function Operational Be sure the battery packs are properly connected and fully charged to 345 bar pressure gauge to the test port on the function manifold Turn key switch to ground controls and pull Emergency Stop buttons out to the ON position Z 34 22 before serial number 153 and Z 34 22N before serial number 304 Move the boom extend retract toggle switch TS13 in the RETRACT direction and check the hydraulic pressure 2 34 22 after serial number 152 and Z 34 22N after 303 Hold the function enable toggle switch TS19 to either side and move the boom extend retract toggle switch TS13 in the RETRACT direction and check the hydraulic pressure Continued on the next page less than 3200 PSI Chart 5 Troubleshoot each function individually OR consult
27. RIGHT mE WH BK TURNTABLE 89 9 a 4 e ROTATE RIGHT 525 2 WH ok E 4 TURNTABLE 55 EFT ROTATE LEFT 5 2 ES 50 0 Ek ET 2 P Q RIGHT C3P 5 C5TRR WH BK caps T 15 65 SB E C3P 4 C4TRLWH 4 8 8 i 2 9s z Z zt E 5 ma om 1 219 Zs e gg SED c RE IBS tt az amp wo Sa a B5 9 a Z m l i 6 26 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 6 Schematics EL M Electrical Schematic 7 34 22 after serial number 4799 Z 34 22N after serial number 5619 C29JSH RD WH First Edition Third Printing Electrical Schematic CE Models 7 34 22 after serial number 4799 7 34 22 after serial number 5619 Section 6 Schematics i i a IIIZ
28. T Jz 9 8 E 1 3 8 ales 16 AUXILIARY LIFT El fw C49 1 R27AUX RD PUMP PR3 a d 2 1 s C133PLABLIRD C2B i 1 1g 5 5 E Jo amp De oo oo 22222022 2 SSS ee UE X P22BATBK C7B 1 f m C49 11 C19LPE GR WH 81 8 PRIMARY LIFT PUMP 2s CONTACTOR RELAY x 1 3 8 Bn 1 3 amp 55 4 RI9LPE GRWH n p PRIMARY LIFT e feo gi PUMP PR2 lt lt gt OU gt Eu Ell 2910 g z 5 E C9HRN BK RD 85 8 BRN HORN s A mu RELAY 77 g BK 8 ws 3 2 HORN 1 1 a 8 8 RD E P22LS BK C10 1 BK 7 LS1 EXT RET 3 g P22BAT BK S J2 BK 7 x 1 SC a 5 8 52 1 BK 8 i C11 4 WH 6 9 9 5 E 9 LS2 PRI UP DWN g 5 52 2 WH 8 C11 3 BK6 9 o 3 LS4 SEC UP DWN 4 CONTROLLER STATUS 28 ag LEDL3 4a 8 pU QOR RD ai SS 049 7 CI78CSL Y 5 CHASSIS GROUND E 9 o ae an tan a CRS C49 2 CABBRK BRAKE RELEASE 2 m 8 8 RELAY 5 bd PRI C182PWR 1 1 DRIVE Q E g OR RD CONTACTOR 9 a g ge c z 2 wp C499 OFF LIMT SPD xod g 4 rg 5 sl BUWH INTERLOCK S 1 dre C1P 3_ C29JSH RD WH C1B 3 RD WH POT HI lt 5 IOI E 16 46 2 z 5 8 6 lt C32JSLWH RD 1 6 C496 WH
29. gt xox 1 5 BE RED WHT B ORG BLK 47 Bil 1 BRAKE RELEASE T WHT GRN 2 i uma t REDIT E TRAVEL ALARM i g 3 E SI RED WHT 29 5 BRAKE RELEASE HALF STROKE i 8 aen Ex WHT BLK 31 DRIVE FORWARD RELAY COIL 2 WHT 30 D DRIVE REVERSE RELAY COIL E BLU BLK 37 g STEER RIGHT DERI BLU 36 STEER LEFT x t 8 EB 3 5 B E WHT RED 32 p BRAKE RELEASE 9 8 E PROPORTIONAL a x EISE GPNWHE RED PRESSURE SWITCH al s 7 Bf a3 P a DRIVE l RED 27 4 AUXILIARY CONTROL 7 ENABLE S 5 RELAY COIL Os AUXILARY RED 1 b RED R2 AUXILIARY PUMP zT d o Es RELAY COIL QB Tyr Y B 55 RN WHT o st GRNMHT 3 pg GRNWHT GRNWHT RS E RED 20 GRN WHT A LIFT PUMP 45 CONTACTOR RELAY WHT RED 3 T E E i WHT RED 6 7 PROPORTIONAL FLOW oz CONTROL COIL 884 UP TTT AT EL JIB BOOM UP z JIB BOOM 1 8 i GRN BLK 44 IB B M DOWN 388s DOWN i i JIB BOO ico S258 J Ecce eden UP GRN 1 t 4 i JIB BOOM GRNBLK 1 DOWN i 1 1 vk fy py fof m RIGHT gt 1 gt PLATFORM ROTATE BRN JIB Pl S PLATFORM RIGHT O ROTATE ae PLATFORM ROTATE Pod i LEFT
30. 7 46 8 5 Jib Boom Platform Rotate Manifold Components Z 34 22 before serial number 1734 and Z 34 22N before serial number 2227 sse 7 51 8 6 Jib Boom Platform Rotate Manifold Components Z 34 22 from serial number 1734 to 2005 Z 34 22N from serial number 2227 to 2771 7 52 8 7 Jib Boom Platform Rotate Manifold Components Z 34 22 after serial number 2005 and Z 34 22N 2771 7 53 8 8 Steer Brake Manifold Components Z 34 22 before serial number 781 and Z 34 22N before serial number 1030 7 54 8 9 Steer Brake Manifold Components Z 34 22 from serial number 781 to 1733 Z 34 22N from serial number 1030 2226 7 55 xviii Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing el TABLE OF CONTENTS Section Seven Repair Procedures continued Hydraulic Tank 9 4 Hydraulic Tank ies ice ente cited en eet d tb reir eunt nd 7 56 Turntable Rotation Components 10 1 Turntable Rotation Hydraulic 7 58 Steering Axle Components 11 1 YokeandiEl Dz s etienne hebes lade elude tes 7 59 11 2 Steering Cylinder sssssssssseseeseseseeenee nennen nnne nnn 7 61 11 9 Te cie Ee tte endi E et din 7 61 Non steering
31. Brake circuit 8 Proportional solenoid valve IN ciis 10 12 ft lbs 14 16 z S r Valve Coil Resistance Specification Normally open poppet valve 20V 23 to 250 schematic item H 3 ition 4 Ive 20V 21 to 230 Plug Torque Specifications 4 Description Hex Size Torque Normally closed poppet valve 20V 22 to 240 schematic item L SAE No 2 1 8 50 in Ibs 6 Nm Proportional solenoid valve 20V 18 to 20Q SAE No 4 3 16 13 ft lbs 18 Nm schematic item N 7 54 Genie 7 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 7 Repair Procedures m UH P Pm M me 8 9 MANIFOLDS Steer Brake Manifold Components Z 34 22 from serial number 781 to 1733 and Z 34 22N from serial number 1030 to 2226 Index No Oo CO nm Schematic Description Item Function Torque Normally open poppet valve 25 30 ft lbs 34 41 position 4 way spool valve Dosen Steer 10 12 ft Ibs 14 16Nm Pressure switch Brake circuit Orifice 0 040 inch 1 02 mm Brake circuit Normal
32. Third Printing 20V or more Press down the foot switch and move the drive controller to full FORWARD direction and check voltage at org blk wire on PR1 20V or Press down the foot more switch and move the drive contoller to full FORWARD direction and check voltage at org blk wire at TB41 Press down the foot 20V or switch and move the more drive controller in the FORWARD direction and check voltage at terminal X on the drive controller oV Press down the foot switch and move the drive controller in the FORWARD direction and check voltage at terminal on the drive controller 20V or more Repair or replace the drive controller Repair open in ground wire circuit to PR1 OR replace PR1 Repair open in org blk wire circuit from TB41 to PRI Repair open in org blk wire circuit from terminal X on the drive controller to 41 Z 34 22 before serial number 153 and Z34 22N before serial number 304 Repair open in power circuit from drive enable toggle switch TS9 to TB12 to LS3 to TB16 to terminal on the drive controller Z 34 22 after serial number 152 and Z34 22N after serial number 303 Repair open in power circuit from drive enable toggle switch TS9 to TB12 to LS3 to TB16 to CR5 to the drive controller OR replace CR5 OR consult Genie Industries Service Department 5 102 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third
33. 2 BLK RED 3 BLK RED 9 ze 4 HORN COIL gt 0 B 5k RED BLK 1 2 RED BLK amp 28 oz ui 24 gt 1 gt ubi cr Pod iu 5 i E tg i RED 2 WHTs23 TILT LEVEL SENSOR 98 wes ogee oe BLK2 afl B 3 AO FLASHING BEACON Xs DNE OPTION 9 ee ee 1 8 3 c 1 0 HUE RED RED R BLK REDRRI WHT 52 WHT 52 1 49 BLK 49 WHT 23 E mu eg ORG BLK 41 4 DRIVE x9 55 MASTER RELAY Ax m 36 2 9 Fa g 2 ORG 1 Jl RED WHT 3 p eco ORG RED 1 T 5 8 E 5 ORG BLK 41 Es gs Sit e EEE ets gt i 5 2 REDWHT 3 z i i gt 1 gt De E e 5 ot H NON Sek m 8 DRIVE MOTOR eL Ty SYSTEM 9 3 MEN l lt aoe 4 ig 1 i H 5 ase i tr tz i Etam 8 lt T IBS rs ds gt H WHT 2 lt 2 Pvt s ES Nggo o BLK RED 3 a plo tin ae PRIMARY 2 Gy PUMP MOTOR i NS ees 2 c E bus AUXILIARY m S 5 5 gt PUMP MOTOR 2 Lr 5 Sub Lcecdeconenen SUN s eap B a
34. 6 5 LoadSensor Option Diagram Z 34 22 from serial number 2061 to 3577 and Z 34 22N from serial number 2871 4260 6 6 Power Cable Diagram Z 34 22 before serial number 3578 and Z 34 22N before 4261 nenne 6 7 Power Cable Diagram Z 34 22 after serial number 3577 and Z 34 22N after serialnumber 4260 2 0000 6 8 Abbreviations Legend 6 9 Electrical Symbols Legend sesssssssssseeeeseeeeeeeneeneee nnne 6 10 Hydraulic Symbols Legend sssssssseeeeseseeeeee eene eene nnne 6 11 Part No 36540 Genie Z 34 22 amp Genie Z 34 22N Xiii First Edition Third Printing TABLE CONTENTS Section Six Schematics continued Electrical Schematic Z 34 22 before serial number 153 and Z 34 22N before serial number 304 6 13 Electrical Schematic Z 34 22 from serial number 153 to 1733 and Z 34 22N from serial number 304 to 2226 6 15 Electrical Schematic Z 34 22 from serial number 1734 to 1834 and 2 34 22 from serial number 2227 to 2447 6 17 Electrical Schematic Z 34 22 from serial number 1835 to 2060 and 2 34 22 from serial number 24481102870 6 19 Electrical Schematic Z 34 22 from serial number 2061 to 3577 and Z 34 22N from serial numbe
35. AWARNING died injury hazard Spraying ydraulic 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 19 Lower the booms to the stowed position 20 Pull all the cables and hoses through the upper mid pivot Component damage hazard CAUTION Cables and hoses can be damaged if they are kinked or pinched 21 Position the strap from the overhead crane approximately 2 feet 0 6 m from the platform end of the primary boom Measure from the end of the primary boom tube 22 Remove the pin retaining fasteners from the upper mid pivot to upper 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 retainers from the upper mid pivot to upper secondary boom pivot pin Use a soft metal drift to remove the pin 25 Carefully remove the entire primary boom assembly primary boom assembly jib boom assembly platform master cylinder primary lift cylinder and upper mid pivot from the machine AWARNING Crushing hazard If the overhead crane is not properly attached the primary boom assembly may become unbalanced and fall when itis removed from the machine Do not remove the assembly from machine until it is properly balanced 26 Place the entire assembly onto a structure capable of supporting it 27 Remove
36. BLK RED 1 ORG 1 ORG BLK 1 TS9 TS7 912 x ed i 5 CAS OWO O 8 lt 3 1 7511 Joa O 55 5 P2 z n m m o c TAC gj a o E TS13 TS10 a 5 a 8 E 2 9 gt m t i fo GE o 3 o c TS8 E 1 _ 1 5 OPTION r w BRN m LABEL DESORIPTION 988 P2 EMERGENCY STOP BUTTON zo 1 HORN BUTTON 5 o BP1 DP1 DRIVE CONTROLLER v BOOM FUNCTION SPEED CONTROLLER qs AUXILIARY SWITCH em PLATFORM ROTATE SWITCH JIB UP DOWN SWITCH TS9 PLATFORM LEVEL SWITCH 4 TS10 SECONDARY BOOM UP DOWN SWITCH Ts12 TURNTABLE ROTATE SWITCH RED BLK T513 EXTEND RETRACT SWITCH Tsis DRIVE ENABLE SWITCH RED l 6 CENE DP1 L R d BATTERY CHARGE INDICATOR OPTION ua TET ALARM LED 1 2 3 4 5 6 7 8 9 10 um 148 PLATFORM OVERLOAD LED 148 7 ND GRN BLK c NOTES lt a REMOVE JUMPER JP1 FOR CE VERSION o w n 2 2 5 5 5 5 m m 2 o o 59 5 zs B lt gt 2 o B E amp 65555 5 Ele g is 8 90502 2 22 2 a le fg fg 8 fe jf JP 5 A gt 50813 o 8 8 gt 6 8 5 JF IS 89 B IE a 5 e a a
37. Be sure the batteries are properly connected and fully charged Be sure the machine is not in the free wheel configuration Be sure the unit is in the fully stowed position with the boom located between the non steer end tires Block the steer wheels and raise the machine so the drive tires are off 196 the ground Turn key switch to platform controls and pull both Emergency Stop buttons out to the ON position Press down the foot switch and move the drive controller in either direction Have someone try to rotate the drive tires by hand Note this will require 2 people tires move Press down the foot 20V or switch and move the more drive contoller in the FORWARD direction Check voltage at terminal 5 on the drive controller ov Continued on the next page Go to Chart 30 Brake Release Function Inoperative Press down the foot switch and check voltage on terminal 4 on the drive controller 20V or more Press down the foot switch and move the drive controller in the FORWARD direction Check voltage at pin 10 on the motor controller harness connector 20V or more Press down the foot switch and move the drive controller in the REVERSE direction Check voltage on terminal 3 on the drive controller 20V or more Press down the foot switch and move the drive controller in the REVERSE direction Check voltage at pin 11 on the motor controller harne
38. Q 2 P1 ONCO 3 BRAKE 4 KS1 1 olo RELEASE NO NO OIO 5 TS15 TS13 6 1514 7512 O O O Q O O 7 1516 1511 o E O O O 8 517 O O TS10 G CR2 eG 52124 52 4 1211416 6 GRN WHT TB19D RED PR4 GRN WHT PR3 CR1 oe is 1 BLK RED TB9D 315 o 211416 6 8 GRN YEL GROUND BLK HORN RED SP WHT HORN LIMIT SWITCH LS1 WIRING LS2 EXTEND RETRACT PRIMARY BOOM LIMIT SWITCH LIMIT SWITCH BLK 49 TB49D WHT 40 TB40D NC NC ele ele WHT 23 TB23D BLK 49 TB49C LS3 LS4 DRIVE ENABLE SECONDARY BOOM LIMIT SWITCH LIMIT SWITCH jn BLK 12 TB12A GRN GROUND BLK 40 TB40B ole os WHT 13 TB13A WHT 52 TB52B RED 16 TB16D Note LS4 added after serial number 950 LABEL DESCRIPTION P1 EMERGENCY STOP BUTTON KS1 KEY SWITCH TS10 TURNTABLE ROTATE SWITCH TS11 SECONDARY BOOM SWITCH TS12 PRIMARY BOOM SWITCH TS13 EXTEND RETRACT SWITCH TS14 PLATFORM LEVEL SWITCH TS15 PLATFORM ROTATE SWITCH TS16 JIB SWITCH TS17 AUXILIARY SWITCH CB1 15amp CIRCUIT BREAKER HM HOUR METER CR1 CONTROL RELAY HORN CR2 CONTROL RELAY AUXILIARY PUMP A2 TRAVEL ALARM A3 DESCENT ALARM
39. Repair Procedures First Edition Third Printing Turntable Rotation Components 10 1 Turntable Rotation Hydraulic Motor The turntable rotation hydraulic motor is the only serviceable component of the turntable rotation assembly The worm gear must not be removed from the housing In order to remove the housing the turntable has to be removed How to Remove the Turntable Rotation Motor When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two 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 Bodily injury hazard Spraying AWARNING 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 7 58 Genie 7 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 7 Repair Procedures Steer Axle Components 11 1 4 Remove the lug nuts Remove the tire and Yoke and Hub wheel assembly 5 Remove the cotter pin and the clevis pin from How to Remove the Yoke both the steering cylinder and the tie rod and Hub Always replace the cotter pin with a new one wh
40. WHT RED 6 TB44 GRN 1 GRN BLK 1 1 PLATFORM ROTATE RIGHT BLK JIB WHT JIB TB18 A PLATFORM ROTATE LEFT PLATFORM LEVEL CUTOUT CE OPTION PLATFORM ROTATE TB17 GRN BLK 3 PLATFORM ROTATE ORG 6 GRN 3 H 14 PLATFORM LEVEL UP BLU JIB ORG JIB PLATFORM LEVEL DOWN 4 ORG 3 JIB MANIFOLD GROUND PLATFORM LEVEL PLATFROM LEVEL MANIFOLD FUNCTION GROUND ORG BLK 3 TB7 PRIMARY BOOM EXTEND BLK 7 4 BLK WHT 8 4 PRIMARY BOOM RETRACT PRIMARY BOOM TB8 BLK 3 PRIMARY BOOM BLK WHT 3 TB1 RED 1 PRIMARY BOOM UP RED BLK 2 PRIMARY BOOM DOWN PRIMARY BOOM RED 3 PRIMARY BOOM RED BLK 3 TB10 BLU 10 SECONDARY BOOM UP BLU BLK 11 SECONDARY BOOM DOWN SECONDARY 11 DESCENT ALARM OPTION BLU 3 SECONDARY BLU BLK 3 WHT BLK 5 TURNTABLE ROTATE RIGHT R fe TBS WHT 4 TURNTABLE ROTATE LEFT TURNTABLE ROTATE BI WHT BLK 3 HP 55 WHT 3 ORG RED 1 ORG RED WHT BLK 1 RED WHT 1 WHT RED 1 BLUWHT 12 BLK 24V RED RED GND GND BRN PR2 2
41. WHT RED 1 WHT RED 1 ter ORG 40 i us BLK 8 te eee Ses RUM S ENE ENA MENS rx c 1 ORG RED CR2 8 2 BLUMWHT 12 154 RED B 85 CRS 5 10a Fi 7 i RED RED 500A Ld 86 4 E w 2 vs t g m PRI x E 9 7855 4 1 9 50 2 g 5 i eese E Ex 5 2 3 FUNCTION F2 m zi m m ENABLE 100A 22 T 2 E 25 a L37 Y gt 2 23 TB28 5 go AA QM m 3 BED g 4 182 s 221 TB9 2 d m o 0 o m m 8 30 CR2 86 amp a3 x 2 mz 2 z 5 34 G s v1 3 2 d j Z Je 2 m 2 2 2 5 5 2 9 I TB49 a a 87 85 8 2 jo m x JA amp 5 8 m 2 1 9 10 4 2 16 14 3 20 E BLK 22 5 BLK 17 5 E s 8 86 CR 30 8 STATUS LED 4 EI 5 CURTIS 1244 5 400A SEPEX CONTROLLER 151 lt 3 oe 092 59 137 24V oum 7 2 FA M B F2 8 n8 S PRS PR2 9 SE b E S m I 2 1 Pw E DL 30 56 6 F2 A2 A2 F1 Bo Bo N 5 1 8 3 4 55 i coon 920008 5 1 LEFT F 1 A1 F2 RIGHT E 9 i MOTOR MOTOR 5 1 H2 B l 9 1 I 2 GROUND H i 8
42. g 22 ma ile i S T r i 8 amp si 2 3 B 9 g 2 lt p 8 amp 2 E i m 5 i 2 2 Li z d gm 5 5 1 49 g m m 5 o 5 im a j 9 g 4 8 m n 5 epe 1 9 10 11 2 16 14 3 20 m 6 2 n 3 8 38 BLK 5 STATUS LED 2 SEPEX CONTROLLER 0 151 100 eo i RED lt RED B 992 2592 13 24V 1 5 Fi M B F2 29 ro E PR3 PR2 9 BE t a e s AS og m 2 B T 1 Hl 2774 22 B 7 A 1 1 gt NOTES 9 F2 A2 A2 F1 S i a 2 s d 1 ALL LIMIT SWITCHES WITH BOOM IN STOWED POSITION EXCEPT AS NOTED 2 I T Ir o o 3 I 0 0090 304 Mew lt 2 SWITCH SHOWN WITH BOOM EXTENDED i tI E 200000 X natn n ZEE ie SWITCH SHOWN WITH BOOM ROATED PAST EITHER NON STEER WHEEL X w IL i 1 Al AT F2 87 85 s lt 4 COIL SUPPRESION DIODE FOR PR1 IS INSIDE CONTROLLER BETWEEN J1 9 AND J1 17 i 1 Pump E m A LEFT MOTOR RIGHT MOTOR i 5 CONTROLED DOCUMENT CHANGES MUST BE APPROVED BY FACTORY MUTUAL FOR EE CERTIFICATION i B 1 4 z 3 HUE call i tt GROUND H2 w w w i
43. press down the foot switch and move the platform rotate toggle switch 2 34 22 before serial number 1734 and Z 34 22N before serial number 2227 TS6 Z 34 22 after serial number 1733 and Z 34 22N after serial number 2226 57 in the RIGHT direction Check voltage at TP6 24N Continued on the next page 5 84 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 5 Troubleshooting Flow Charts 21 Press down the foot Repair open in grn wht switch and move the wire circuit through platform rotate toggle boom function toggle Switch in the RIGHT switches to the red wire direction Check voltage on the boom function atthe red wire on the speed controller boom function speed controller Continued from the previous page Press down the foot Repair open in ground switch and move the wire circuit from the platform rotate toggle boom function speed switch in the RIGHT controller to ground OR direction Check voltage replace the boom at the blk red wire on the function speed boom function speed controller controller Repair open in blk red wire from the boom function speed controller to TB6 Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 5 85 Section 5 Troubleshooting Flow Charts CHART 21 Continued from page 84 Turn key switch to ground controls and pull both Emergency Stop buttons out to the posi
44. 2 34 22 before serial number 153 and Z34 22N before serial number 304 Repair open in org red 3 wire circuit from TB16 to terminal on the drive controller 2 34 22 from serial number 153 to 1733 and Z 34 22N from serial number 304 to 2226 Repair open in org red wire circuit from TB16 to CR5 OR repair open in ground wire circuit from CR5 to ground OR repair open in blu wht wire circuit from center pole at TS9 to CR5 OR repair open in wire circuit from CR5 to terminal on the drive controller OR replace CRS Repair or replace LS3 Part No 36540 Genie Z 34 22 amp Genie Z 34 22N Section 5 Troubleshooting Flow Charts First Edition Third Printing CHART 37 Press down the foot switch and hold the drive enable toggle switch TS9 to either side and check voltage on terminal on drive controller Continued from the previous page Adjust drive controller OR replace drive controller OR consult Genie Industries Service Department Repair open in wire circuit from drive enable toggle switch TS9 to terminal on drive controller OR replace TS9 OR consult Genie Industries Service Department 5 128 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 5 Troubleshooting Flow Charts Drive Enable System Is Malfunctioning Z 34 22 after serial number 1733 and Z 34 22N after serial number 2226 Be sure the machine
45. 3 1 mph 40 ft 9 1 sec 6 4 km h 12 2 m 6 8 sec 5 km h 12 2 m 9 1 sec after serial number 1733 Drive speed stowed 47 1 torque hubs 3 7 mph 40 ft 7 5 sec 6 km h 12 2 m 7 5 sec Drive speed 0 6 mph booms raised or extended 40 ft 40 sec Drive speeds maximum Z 34 22N before serial number 2227 1 km h 12 2 m 40 sec Drive speed stowed 3 4 mph 5 5 km h 35 1 torque hubs 40 fU8 12 2 m 8 sec Drive speed stowed 2 8 mph 4 5 km h 49 1 torque hubs 40 fU10 12 2 10 sec after serial number 2226 Drive speed stowed 3 1 mph 5 km h 47 1 torque hubs 40 fU9 sec 12 2 m 9 sec Drive speed 0 6 mph 1 km h booms raised or extended 40 ft 40 sec Gradeability boom stowed Z 34 22 before serial number 1734 49 1 drive hubs 35 1 drive hubs Z 34 22 after serial number 1733 47 1 drive hubs Z 34 22N before serial number 2227 49 1 drive hubs 35 1 drive hubs Z 34 22N after serial number 2226 47 1 drive hubs 12 2 m 40 sec 3576 30 30 25 20 30 First Edition Third Printing SE nl Boom function speeds maximum from platform controls with 500 Ibs in platform Z 34 22 before serial number 1734 and Z 34 22N before serial number 2227 Jib boom up 30 to 40 seconds Jib boom down 15 to 25 seconds Primary boom up 25 to 35 seconds Primary boom down 15 to 25 seconds Primary boom extend 25 to 35 seconds Primary boom retract
46. 45383 Floyd Bell Inc MW 09 530 Q 1 H2 3 usus Horn 24V DC 108 GB 56265 FIAMM rens 4324021 iesu 1 HS uiis Alarm intermittent 18963 Floyd Bell Inc XB 09 630 Q 1 HA Alarm chime tone 45462 Floyd Bell Inc 09 525 1 HM Hour meter 56100 Curtis Instruments 14305628 rre 1 This list continues on the next page 6 2 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 6 Schematics ELECTRICAL COMPONENTS Item Description Genie Part Manufacturer Manufacturer Qty Number Part Number KS1 Contact Key switch 45081 Telemecanique ZB2 BE101 2 151 164 Contact Limit switch 19491 Telemecanique XESP2051 1 Level sensor Level sensor 4 5 ANSI amp CSA 44586 Power Comp of Midwest zi T conte 1 Motor controller Curtis 23314 Curtis Instruments
47. Before serial number 674 item AB From serial number 674 to 1733 item BB After serial number 1733 item CR Z 34 22N Before serial number 935 item AB From serial number 935 to 2226 item BB After serial number 2226 item CR 5 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the relief valve cap AWARNING hazard Do not adjust the relief valve higher than specified 6 Repeat steps 2 and 3 to confirm the relief valve pressure setting Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 7 Repair Procedures How to Adjust the Primary Boom Down Relief Valve Perform this procedure with the boom in the stowed position 1 Connect 0 to 3000 psi 0 to 206 bar pressure gauge to the test port on the function manifold 2 Turn the key switch to ground control and pull out the Emergency Stop button to the position 3 Z 34 22 before serial number 153 and Z 34 22N before serial number 304 Move 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 Z 34 22 after serial number 152 and Z 34 22N after serial number 303 Hold the function enable toggle switch to either side and move the primary boom up down toggle switch in the down direction with the primary boom fu
48. Genie Service Manual Part No 36540 Rev August 2008 2 34 22 before serial number 6291 2 34 22 DC ad before serial number 5427 Introduction First Edition Third Printing Genie Z 34 22 Genie 2 34 22 Important Read understand and obey the safety rules and operating instructions in the Genie 2 34 22 amp Genie Z 34 22N Operator s Manual before attempting any maintenance or repair procedure This manual provides detailed scheduled maintenance information for the machine owner and user It also provides troubleshooting and repair procedures for qualified service professionals Basic mechanical hydraulic and electrical skills are required to perform most procedures However several procedures require specialized skills tools lifting equipment and a suitable workshop In these instances we strongly recommend that maintenance and repair be performed at an authorized Genie dealer Service center Genie Industries has endeavored to deliver the highest degree of accuracy possible However continuous improvement of our products is a Genie policy Therefore product specifications are subject to change without notice Readers are encouraged to notify Genie of errors and send in suggestions for improvement All communications will be carefully considered for future printings of this and other manuals Please write to the technical publications team in care o
49. IN el E ru 5 5 Cz S og E 7 REVERSE _ x 2 m WHT BLK431 8 1 i FORWARD 800 o bo X gt 5 DIODE RETURN a m 9 5 48V INPUT m RG RED o T DRIVE CONTACTOR y SMOD RED WHT d BLK Fa BLK _ 48V BATTER i 5 Us i E 5 d WHT Y CHARGER 1 2 amp 9o E NNNM ee N ud a u 5 ET mE i BLK PRIMARY lt d oue uec x 52 ub EE ee RE BLK AUXILIARY gt 8 co Lu m mos zl 55 PS EB T o x RED CB1 o 9850 F 7 oto EE 2 2 MA ie vale x z N amp 8 ER 2 a 9s ete lle Ella ae 1 zr Fo lt I xa 4 9 81 L i _t lt e eem iO N Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 6 17 Jumper remove for CE version Section 6 Schematics Electrical Schematic Z 34 22 from serial number 1734 to 1834 Z 34 22N from serial number 2227 to 2447 First Edition Third Printing LVI BCI OPTION Se cisco See S
50. P3 Toggle switch HORN FM DPDT Circuits crossing no connection AHOIW 1 Horn button normally open PLATFORM KS1 t FSt BLK GROUND m Key switch Auxiliary lift pump E a Diode L E Foot switch Pla PSH Emergency Pressure Stop button 6 switch normally closed Battery 6 10 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 6 Schematics O Hydraulic filter o Check valve i d ants 0 045 1 14 MM Orifice with size 7 Double acting cylinder motor Pressure switch T Fixed displacement pump d Bi directional motor ert Solenoid operated dump valve 2800 psi 193 bar Relief valve amp lt gt Filter with by pass Hydraulic Symbols Legend I Solenoid operated 3 position 4 way directional valve 001 or D03 pei 280 uc fen ed 3000 PSI 207 bar 3 1 Counterbalance valve 77 me Differential sensing valve FAN Solenoid operated proportional valve n Solenoid operated 2 position 3 way directional valve IO E Normally closed poppet valve
51. RED BLK SENSOR RED WHT 23 PEE Tee FLASHING EU e BEACON OPTION WHT 2 FL i amp 4 WHT 23A HORN E 8 BLK RED CR4 Sa BLK RED 3 m 1 amp O5 a E HORN Ek 222 BLKIRED HO BLK 22 8 a I n T 5 gutem iq BLK 7 WHT 7 LIMIT SW IS a P ing i N te za 4 c 5g ads i 505 f 52 Ca Esg amp g DS PRIMARY BOOM o 3 LIMIT SWITCH LS2 5 ake 168 o 6 E 2 2 d g SECONDARY 2 LIMIT SWITCH LS4 amp 9 40 BLK 8 WHT 8 16 d J 2 1 J CONTROLLER 8 vex BLK FAULT INDICATOR EL Hp ORG RED 42 iek a AM DRIVE amp GRN TO g S CONTAC 8 B FL ORG RED COIL T wi BLK T Pee ea ee NNNM T4 10 o Oh REDIBLK BR amp Sg T PEED INPUT 8 ORG 40 OFF LIMIT S o 9s POT LOW E WHT RED 432 9 A 191 aL WIRE POT x RED WHT 29 zw 2 i 2 g gt ITERLOCK O 8 BLU WHT 12
52. RED WHT E H mz ct 6 SSE 8 i 1 E BLU 36 1 BLU 1 i a i I i 5 8 T BLU BLK 1 BLU BLK 37 1 i 1 5 a L f f o 294 Y vey t 1 E BC 52 S WHT BLK 1 o 1 85 4 4 4 2E Bie zo y 9 i 1 5 lela f RED 27 ie ol i 1 87 8 8 L 4 4 t 1 i 8 z RED 1 aN x Ri 9 p 22 5 GRNWHT 8 E 1 ORG RED w sf a 1 2g z B EU 08 T 2 E ORG 2 4 O 23 m WHT RED 3 8 S s RED P 2 gt A Oj 5 eb ff S i GRNWHT 3 GRNWHT E WHT RED 6 WHT uno NA e ejje Y i 1 a 4 a 2 ly x X 1 8 z 81 g a A 5 5 SAI X 4d Lf m i 3 aa 5255 z 2828 E A e 1 E a E 1 0 fey 1 1 E 1 I 1 1 t 1 d GRNA i I I GRN BLK 1 PO 4 4 1 1 1 i 2 25 4 og p T 4 3r gt a zi i 1 E I Ex 1 1 35 1 1 1 ow i 9 1 A CRNBLK S f
53. Table A Procedures A 1 Inspect the Operator s and Safety Manuals 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 1 Checkto be sure the storage container is present and in good condition 2 Check to make sure that the operator s responsibilities and safety manuals are present and complete in the storage container in the platform 3 Examine the pages of each manual to be sure that they are legible and in good condition 4 Always return the manuals to the storage container after use Contact your authorized Genie distributor or Genie Industries if replacement manuals are needed A 2 Inspect the Decals and Placards Maintaining all of the safety and instructional decals and placards 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 Referto the Decals section in the Genie Z 34 22 amp Genie Z 34 22N Operator s Manual and use the decal list and
54. ZO EL IOS I EQ i RIGHT GRN BLK 3 Ol PLATFORM Lo i ROTATE Gans i e LEFT No RED Jp 08 i ki MEM 11001 T Oo 5 06 ig Si z UP p RHA Pi PLATFORM LEVEL UP pao PLATFORM LEVEL EE ORG BLK 15 D DOWN e d PLATFORM LEVEL DOWN t e zi 1 UP ORG 3 I PLATFORM LEVEL ORG BLK 3 DOWN aM i i EXTEND Fa PEKEZ PRIMARY BOOM EXTEND PRIMARY g i o BOOM BLK WHT 8 P in BETHACT s PRIMARY BOOM RETRACT BLK 3 PRIMARY BOOM BLK WHT 3 RETRACT 1 i RENE S z x ig i SEE ES Sa 98 a i tr z ommsz o 2 8 6 16 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 6 Schematics Electrical Schematic Z 34 22 from serial number 153 to 1733 Z 34 22N from serial number 304 to 2226 First Edition T
55. e d CUM RED 1 WHT 4 TS16 511 TS10 GRN BLK 44 o d A PTT GRN 43 EM E BLU 10 RED 20 BLU BLK 11 WHT BLK 5 H G F CR2 AUXILIARY PUMP 0 9 515 19 RED TB27D 44 8 BRN CR4 246 71 6 8 GRN WHT TB19D RED CH GRN WHT CH CR1 HORN 09 76 2 eu 55 7 BLK RED TB9A 6 2 1416 8 BRN MH BLK HORN RED SP WHT HORN CR4 PLATFORM LEVEL CUT OUT OPTION ORG TB14D eG 5 2 7 tette i 9 9 RED LS2 BRN TB51A BRN CR2 ORG BLK TB15D ORG BLK MH ORG MH LS1 LS2 EXTEND RETRACT PRIMARY BOOM LIMIT SWITCH LIMIT SWITCH BLK 49 TB49D ORG TB14D TB15D 4 1 BLK TB49C WHT 40 TB40D WHT 23 TB23C RED CR4 LS3 LS4 DRIVE ENABLE SECONDARY BOOM LIMIT SWITCH LIMIT SWITCH eT BLK 12 TB12B 0 E BRN TB50B ia N c BLK 40 TB40B WHT 13 TB13B WHT 52 TB52B RED 16 TB16B LABEL DESCRIPTION P1 EMERGENCY STOP BUTTON KS1 KEY SWITCH TS10 TURNTABLE ROTATE SWITCH 1811 SECONDARY BOOM UP DOWN SWITCH 1512 PRIMARY BOOM UP DOWN SWITCH 1513 BOOM EXTEND RETRACT SWITCH 1514 PLATFORM LEVEL SWITCH TS15 PLATFORM ROTATE SWITCH TS16 JIB UP DOWN SWITCH TS17 AUXILIARY SWITCH TS19 FUNCTION ENABLE SWITCH CB1 CIRCUIT BRE
56. ee eee a COD y Section 7 Repair Procedures First Edition Third Printing PLATFORM CONTROLS 9 Turn the key switch to platform controls and pull both Emergency Stop buttons out to the oN position 10 Set the threshold on the brake circuit board Press down the foot switch and slowly move the control handle off center until you hear the pump motor turn Adjust the amperage to 0 16 amps Turn the threshold trimpot adjustment screw clockwise to increase the amperage or counterclockwise to decrease the amperage 11 Set the max out on the brake circuit board Press down the foot switch and slowly move the control handle off center until you hear the pump motor turn orr Adjust the amperage to 0 91 amps Turn the max out trimpot adjustment screw clockwise to increase the amperage or counterclockwise to decrease the amperage 12 Set the threshold on the drive circuit board Press down the foot switch and slowly move the control handle off center until you see 0 28 to 0 3 amps on the ammeter Adjust the threshold trimpot on the drive circuit board to 0 8 to 0 9V DC Turn the threshold trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage 13 Set the max out on the drive circuit board Press down the foot switch and slowly move the control handle all the way to the FoRwARD position Adjust the max out trimpot on the drive circuit board to 5 to 5 2V DC Turn the ma
57. n NON STEER AXLE COMPONENTS 5 Centera lifting jack under the non steer end of the machine Raise the machine approximately 6 inches 15 cm and place blocks under the chassis for support 6 Remove the wheel lug nuts Remove the tire and wheel assembly 7 Place a second lifting jack under the drive hub for support Secure the drive hub to the lifting jack 8 Remove the brake mounting bolts Remove the brake from the machine 9 Remove the drive hub mounting bolts Remove the drive hub from the machine A CAUTION Crushing hazard The drive hub may become unbalanced and fall when the mounting fasteners are removed if it is not properly supported and secured to the lifting jack Torque specifications Lug nuts dry 125 ft lbs 169 5 Nm Lug nuts lubricated 94 ft lbs 127 Nm Drive hub bolts dry 210 ft lbs 285 Nm Drive hub bolts lubricated 94 ft lbs 127 Nm Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 7 63 Section 7 Repair Procedures First Edition Third Printing Motor Controller 13 1 Motor Controller Z 34 22 after serial number 1733 and Z 34 22N after serial number 2226 The drive motor controller is located under the non steer end drive chassis cover The drive motor controller can recognize machine drive 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
58. 15 to 25 seconds Secondary boom up 15 to 25 seconds Secondary boom down 10 to 15 seconds Turntable rotate 355 50 to 70 seconds Platform rotate 160 5 to 10 seconds Platform level up 10 to 20 seconds Platform level down 10 to 20 seconds Boom function speeds maximum from platform controls with 500 Ibs in platform Z 34 22 after serial number 1733 and Z 34 22N after serial number 2226 Jib boom up 23 to 29 seconds Jib boom down 20 to 26 seconds Primary boom up 15 to 21 seconds Primary boom down 12 to 18 seconds Primary boom extend 21 to 27 seconds Primary boom retract 12 to 18 seconds Secondary boom up 16 to 22 seconds Secondary boom down 12 to 18 seconds Turntable rotate 355 57 to 63 seconds Platform rotate 160 17 to 23 seconds Platform level up 10 to 20 seconds Platform level down 10 to 20 seconds Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 2 Specifications Hydraulic Specifications Hydraulic fluid Dexron equivalent Liftpump Type Fixed displacement gear pump Displacement 0 153 cu in per revolution 2 5 cc Displacement 1 6 gpm 2500 psi 172 bar 6 l min Hydraulic reservoir return line filter 10 micron with 25 psi 1 7 bar bypass Function manifold Function relief 3200 psi
59. 30 on CR1 OR repair open in org red CR2 from the 10A fuse F5 to terminal 30 on CR2 OR replace CR2 Repair open in brn ground wire from terminal 86 on CR1 to ground OR repair open in red wht wire from TB3 to terminal 85 on CR1 OR replace CR1 5 114 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Continued from the previous page Check voltage on the battery cable on the input side of PR1 48V Press down the foot switch and check voltage at TB12 20V or more Press down the foot switch and check voltage at pin 2 on the motor controller harness connector 20V or more Turn key switch to the OFF position Wait for 5 seconds and turn the key switch to platform controls Do not press down the foot switch Check voltage at the grn wire on PR1 48V Remove the diode from and install it onto yes PR1 with the band on the diode aligned with the org red 42 wire Push in the Emergency Stop button to the OFF position and wait for 5 seconds then pull out the Emergency Stop button to the ON sition Press down the oot switch and test the drive function Does the machine drive no Continued on the next page Section 5 Troubleshooting Flow Charts LL e n i LL LL LL LLL Repair open in cable circuit from battery packs to 500A fuse F4 OR replace the 500A fuse F4 Repair open in blu wht wire fr
60. 4 11 Check the Batteries siii na a 4 12 Inspect the Electrical 4 13 Inspect the Tires and Wheels including lug nut torque 4 14 Confirm the Proper Brake Configuration 2 2 2 0 4 14 Check the Oil Level in the Drive 5 4 15 Test the Key Switch ette erect gene ertet ed e 4 16 Test the Emergency Stop 4 16 Test the Ground 4 17 Test the Platform Self leveling 2 2 2 4 17 Testthe born iiie eei tL diee R 4 18 Lest the Foot Cre a d a eq ee e s 4 18 Test the Drive Enable System sssssssssssseeeneeeneeen nen 4 19 Test the Drive 22 nnne 4 20 Test the Drive Speed Stowed Position 2 4 21 Test the Drive Speed Raised or Extended Position 4 22 Test the Alarm Package 4 23 viii Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Es TABLE OF CONTENTS Section Four Scheduled Maintenance Procedures continued 17 Testthe Turntable Rotation 2 2 2 4020 0 4 24 B 18 Check the Electrical Contactors 0 00 1000 4 25 B 19 Perform Hydraulic Analysis
61. 5 nur o i i I 1 1 GRN 3 t jx J B i a m aj 5 Ini o I 415 1 44 at m ide 5 9 sa eke eet E 51 eu 1 za 9 Epz 5 1 228 ga 1 Sir 1 2s 5 ORG 3 1 t ORGIBLK 3 i 1 5 E BLK 7 i is T 4 i I 8 1 7 E BLKWHT 8 38 3 i i l oa 1 1 1 gt fs k 55 5 g i1 BLK WHT 3 1 5 1 s TN E t RED BLK 2 gs 8 29 i 1 gt 2 i 1 5 s 28 5 0 1 RED 3 Eg 1 RED BLK 3 5 m BLU 10 1 i E B 5 t m BLU BLK 11 4 B z ie 554217 uo 98 i m e lt 2 E 85 al BLU 3 oai ID eee t BLU BLK 3 1 amp WHT BLK 5 Hl i gt 4 4 B Em E WHT 4 n ER 55 1 I ul i i 8 WHT BLK 3 i PE t WHT 3 i i i 2 E 30088 5 28 8 E a all Eg a t 3 9 2 g E 2 2 zz Sla DRIVE ENABL
62. 8 10 ft Ibs 11 14 Nm 12 2 position 3 way solenoid valve Bl zu Platform level down 8 10 ft lbs 11 14 Nm 13 Orifice 0 050 inch 1 27 mm BM Turntable rotate circuit 14 Counterbalance valve BN Platform level down 35 40 ft Ibs 47 54 Nm 15 Counterbalance valve BO Platform level up 35 40 ft lbs 47 54 Nm 16 Counterbalance valve Turntable rotate right 35 40 ft lbs 47 54 Nm 17 Counterbalance valve BQ Turntable rotate left 35 40 ft lbs 47 54 Nm 18 Relief valve 1600 psi 110 bar BR s Secondary boom down 25 30 ft lbs 34 41 Nm 19 Relief valve 1400 psi 97 bar BS Primary boom down 25 30 ft lbs 34 41 Nm 20 Relief valve 1800 psi 124 bar BT ss Boom extend 25 30 ft lbs 34 41 Nm 21 Proportional solenoid valve BU System flow regulating circuit 10 12 ft lbs 14 16 Nm 22 Diagnostic fitting sese Testing Plug Torque Specifications Description Hex Size Torque Description Hex Size Torque SAE No 2 1 8 50 in lbs 6 Nm SAE No 6 1 4 18 ft lbs 24 Nm SAE No 4 3 16 13 ft lbs 18 Nm SAE No 8 5 16 50 f
63. Be sure the drive hubs are not disengaged Be sure the remote brake release is removed Turn key switch to platform controls and pull both Emergency Stop buttons out to the ON position press down the foot switch and move the drive controller in the FORWARD direction until the first micro switch activates Check voltage at TB19 20V or more Continued on the next page First Edition Third Printing Press down the foot switch and move the drive controller in the 20V or FORWARD direction until the first micro switch activates and check voltage at TB47 more 20V Press down the foot S switch and move the drive controller in the FORWARD direction until the first micro switch activates and check voltage at TB41 Press down the foot 20V or switch and move the more drive controller in the FORWARD direction until the first micro switch activates and check voltage at terminal X on the drive controller oV Press down the foot switch and move the joystick in the FORWARD direction until the first micro switch activates and check voltage at terminal on the drive controller 20V or more Repair or replace drive controller Consult Genie Industries Service Department Repair open in grn wht wire circuit with diode from pressure switch item K to TB19 OR replace pressure switch OR repair open in wire circuit from TB47 to the brake release valve N C item K to pressu
64. C C29JSH RD WH C32JSL WH RD First Edition Third Printing C29JSH RD WH C32JSL WH RD NE FERE 8 40255 5 BRN C7P 3 BATGND BRN C7B 3 BATGND BRN GY 1 C13DEL BURD C4B 1 C13DEL BURD C84 WH 5 um S 5 C82 4 ARK 4 12 4 CI2FTSBL WH C3B 12 C12FTS BLWH BKS 055 C8 1 gt C4P 4 160 OR RD C4B 4 B C16DE OR RD Lai IE OR RD e toy 3 ul RD WH 4 TRAVEL ALARM F 50 ete o 520 8 FA8BRK RD WH 45 BRAKE RELEASE e oe E e o 3 DS Le NC COIL gt 1 1 en BRAKE RELEASE 8 NO COIL v 2On lt 2 Le 5044 woe j PSI 4 BRAKE RELEASE P 4 PRESSURE SWITCH C36SCC iab 1 10 365 BL 1B 10 BL 4 STEER LEFT C8 eje B CiP M 44 C37SCWBUBK 1 11 m BUBK 47 4 STEER RIGHT 1 1 I i x 1 20 r c x e s lo o o zr r T 4 A JE d i 2 EV ELSE lt a c a als c H
65. Genie 7 34 22 amp Genie Z 34 22N 5 25 Section 5 Troubleshooting Flow Charts First Edition Third Printing EE NSN CHART 6 Move the function Repair open in grn wht pig the enable toggle switch to wire circuit with diode P page either side and hold the from TS60 to TB19 OR secondary boom toggle replace the diode switch in the UP direction Check voltage at TB19 Consult Genie Industries Service Department 5 26 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 5 Troubleshooting Flow Charts Platform Controls Inoperative Ground Controls Operate Normally Z 34 22 before serial number 1734 and Z 34 22N before serial number 2227 Be sure key switch is in the appropriate position Be sure the Emergency Stop buttons are pulled out to the oN position Be sure the battery packs are properly connected and fully charged Chart 7 Turn key switch to platform controls and pull both Emergency Stop buttons out to the ON position Check voltage at the red wire Repair open in the red wire circuit from the Emergency Stop button to the input side of the platform controls contact of the key switch on the input side of the platform controls contact of key switch this wire should originate at the Emergency Stop button 20V or more Check voltage at the Check to see if the key Replace the key switch ou
66. Z 34 22 before serial 3200 PSI cylinder s number 153 and counterbalance valve s Z34 22N before serial OR function manifold number 304 Move the could have an internal primary boom extend defect Consult Genie retract function toggle Industries Service switch in the EXTEND Department direction and check the pressure 2 34 22 after serial number 152 and Z34 22N after serial number 303 Hold the function enable toggle Switch to either side and move the primary boom extend retract function toggle switch in the EXTEND direction and check the pressure Continued from the previous page 3200 PSI Check for mechanical restrictions keeping the primary boom extend function from operating OR repair cylinder or cylinder counterbalance valve OR consult Genie Industries Service Department 5 54 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 5 Troubleshooting Flow Charts Primary Boom Retract Function Inoperative Be sure key switch is in the appropriate position Be sure the Emergency Stop buttons are pulled out to the oN position Be sure the battery packs are properly connected and fully charged Turn key switch to ground controls and pull both Emergency Stop buttons out to the ON position 2 34 22 before serial number 153 and Z34 22N before serial number 304 Move the primary boom extend retract toggle switch TS1
67. cap the manifold fittings Move the primary boom toggle switch TS12 in the UP direction Does the platform level Z 34 22 from serial number 153 to 1733 and Z 34 22N from serial number 304 to 2226 Remove both hydraulic hoses from the function manifold ports C1 and C2 Plug the hoses and cap the manifold fittings Hold the function enable switch to either side and move the primary boom toggle switch TS12 in the UP direction Does the platform level Z 34 22 after serial number 1733 and Z 34 22N after serial number 2226 Remove both hydraulic hoses from the function manifold ports L1 and L2 Plug the hoses and cap the manifold fittings Hold the function enable switch to either side and move the primary boom toggle switch TS61 in the UP direction Does the platform level Continued on the next page Chart 17 Replace the counterbalance valves in the function manifold items AN and AO or items BN and BO or items CB and CC Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 5 69 Section 5 Troubleshooting Flow Charts First Edition Third Printing CHART 17 Z 34 22 before serial Install a 010 5000 psi the number 153 and 0 to 345 bar pressure ed ae the page Z34 22N before serial gauge into the barrel y number 304 Plumb 0 end hydraulic hose to 5000 psi 0 to 345 hose connected to bar pressure gauge into less than Port C2 OR L2 from the maste
68. ground wire circuit to boom function proportional valve coil Troubleshoot jib function toggle switches on ground and platform controls OR repair open in wht red 6 wire circuit from ground controls toggle switch to TB6 and from platform controls toggle switch to red wire on boom function speed controller OR consult Genie Industries Service Department If voltage to TB6 from toggle switch at ground control and toggle switch at platform control has been restored and jib up function is still inoperative continue trouble shooting from beginning of chart Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Continued from the previous page Turn key switch to ground controls and pull both Emergency Stop buttons out to the ON position Z 34 22 before serial number 153 and Z34 22N before serial number 304 Move jib toggle switch in the UP direction and check voltage on the blk wire on the jib up directional valve coil item A Z 34 22 after serial number 152 and Z 34 22N after serial number 303 Hold the function enable toggle switch to either side and move jib toggle switch in the UP direction and check voltage on the yel wire on the jib up directional valve coil item A 20V or more Continued on the next page Section 5 Troubleshooting Flow Charts SS SS Z 34 22 before serial number 153 and Z34 22N before serial number 304 Move the jib toggle sw
69. ju e Mi 15 E n 17 E i 4 M 7 B P2 0 050 1 27 mm Ti T Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 6 Schematics Hydraulic Schematic 7 34 22 from serial number 674 to 1733 7 34 22 from serial number 935 to 2226 N M L K G F E D C B A 4 0 1 COM 9 CYLINDER s2 HO ul 51 L 0 040 rey 0 052 BRAKE 2 1 i 1 32 mm 0 085 4 L 2 15 Ux o P STEERIBRAKE oo PLATFORM LEVEL MANIFOLD SLAVE CYLINDER Lact ee p 3 PLATFORM ROTATE PER SECONDARY PRIMARY EXTENSION 4 e o WIE CYLINDER CYLINDER CYLINDER m nap AUXILIARY PRIMARY
70. terminal on the printed circuit board Connect the black lead from an ammeter to the white red wire that was removed from the circuit board Connect the red lead to the B terminal on the printed circuit board Connect the red lead from a volt meter to the D terminal on the drive controller printed circuit board Connect the black lead to ground Turn the key switch to platform control and pull out the Emergency Stop button to the on position at both the ground and platform controls Set the brake threshold on the circuit board Press down the foot switch and slowly move the control handle off center until you hear the pump motor turn on Adjust the amperage to 0 16 amps Turn the threshold trimpot adjustment screw clockwise to increase the amperage or counterclockwise to decrease the amperage Set the brake max out on the circuit board Press down the foot switch and slowly move the control handle off center until you hear the pump motor turn Adjust the amperage to 0 91 amps Turn the max out trimpot adjustment screw clockwise to increase the amperage or counterclockwise to decrease the amperage 10 Set the drive threshold on the circuit board Press down the foot switch and slowly move the control handle off center until you see 0 28 to 0 3 amps on the ammeter Hold the control handle in this position and adjust the drive threshold trimpot on the circuit board to 0 8 to 0 9V DC Turn the threshold
71. wire circuit through boom function toggle switches to the red wire on the boom function speed controller Repair open in ground wire circuit from the boom function speed controller to ground OR replace the boom function speed controller 5 72 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 5 Troubleshooting Flow Charts CHART 18 Continued from page 71 Turn key switch to ground controls and pull both Emergency Stop buttons out to the position Z 34 22 before serial number 153 and Z34 22N before serial number 304 Move platform level toggle switch in the UP direction and check voltage on the org 14 wire on the platform level up directional valve coil item AG Z 34 22 after serial number 152 and Z34 22N after serial number 303 Hold the function enable toggle switch to either side and move platform level toggle switch in the uP direction and check voltage on the org 14 wire on the platform level up directional valve coil item AG or BG or CA 24V Continued on the next page Z 34 22 before serial number 153 and Z34 22N before serial number 304 Move the platform level toggle Switch in the UP direction and check voltage at TB14 2 34 22 after serial number 152 and Z34 22N after serial number 303 Hold the function enable toggle switch to either side and move the platform level toggle switch in the UP direction and ch
72. zo o A d A 10A TB52 2 8 BLK BLK YA GND cge BAN AP1 i 1 L gt cv Ds ac az 2Es AX de gt 4 gt DQ gt 2 EI lt mx vx 6 19 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 NHOH NHOH NOILdO Noovag SNIHSV 14 HOSN3S H3MOd Od A8 H3MOd Od A8r Section 6 Schematics First Edition Third Printing Electrical Schematic 7 34 22 from serial number 1835 to 2060 7 34 22 from serial number 2448 to 2870 JP1 REMOVE FOR CE VERSION OPTION BRN 2 a 8 7 ES m BLU RED 3 WHT 5 BRN 5 fet re fa TALA E 8 3 BLUMWHT 3 BLK S i RED 5 t ie s Y ORG RED 3 9 o Hd WHT EE ORG RED ee y RED WHT i 7 Ja 4 m mg a 5205 RED ES REDMHT 48 l
73. 1 JR o 5 10A E 4 7 BLK Ne BRN BRN TT GND 7 1 1 i 2 BLK 24V L 1 Ez cv CCH DI oua o3 Dy zh 2 E g 6 5 2552 GER 5 mo me LE mz ne lt NS 5 lt x 2 5g 288 22 ET 282 T 58 53 E 8 092 E 2 mo 235 552 59 222 2 EE X Dm ae D 25 zm 3 Q3 9 25 8 gt 5 8 NOTES 1 ALL LIMIT SWITCHES WITH BOOM IN STOWED POSITION EXCEPT AS NOTED lt ADD D40 ONLY IF UNIT HAS L4 amp L48 ESSDCL lt SWITCH SHOWN WITH BOOM EXTENDED lt ANSUCSA lt REDUNDANT COIL SUPPRESION DIODE FOR PR1 IS INSIDE CONTROLLER BETWEEN J1 9 AND J1 17 LIMIT SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON STEER WHEEL lt CE amp PLATFORM LOAD SENSE OPTION 6 23 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 BRN 2 DRIVE ENABLE LED TB13 d BLU RED 3 WHT 5 amp DRIVE ENABLE LED ie 4 foo BLU WHT 3 BLK 5 RED 5 DRIVE ENABLE Section 6 Schematics JP1 REMOVE FOR CE VERSION Electrical Schematic 7 34 22 from serial number 3578 to 4799 Z 34 22N from serial number 4261 to 5619 H TB12 zo LIMIT SWITCH ORG RED 3 DRIVE ENABLE TB16 WHT ORG RED TS15 g TRAVEL ALARM 4 5778 RED WHT BRAKE RELEASE N C VALVE 1 i L RED WHT TB48 RED WHT 48 R
74. 10 ft lbs 11 14 Nm 7 2 position way solenoid valve AG na Platform level up 8 10 ft lbs 11 14 Nm 8 2 position way solenoid valve Boom extend nee 8 10 ft Ibs 11 14 Nm 9 2 position way solenoid valve Al Primary boom 8 10 ft lbs 11 14 Nm 10 2 position way solenoid valve AJ Secondary boom down 8 10 ft lbs 11 14 Nm 11 2 position way solenoid valve AK Turntable rotate right 8 10 ft Ibs 11 14 Nm 12 2 position way solenoid valve AL Platform level down 8 10 ft Ibs 11 14 Nm 13 Orifice 0 050 inch 1 27 mm AM Turntable rotate circuit 14 Counterbalance valve AN Platform level down 35 40 ft lbs 47 54 Nm 15 Counterbalance valve AO Platform level up 35 40 ft lbs 47 54 Nm 16 Relief valve 1750 psi 121 bar Turntable rotate left 25 30 ft Ibs 34 41 Nm 17 Relief valve 1750 psi 121 bar AQ Turntable rotate right 25 30 ft lbs 34 41 Nm 18 Relief valve 1600 psi 110 bar AR Secondary boom down 25 30 ft Ibs 34 41 Nm 19 R
75. 3 wire circuit from toggle switch to TB4 OR replace toggle switch 5 62 Genie 2 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 5 Troubleshooting Flow Charts 0 or infinite ohms Disconnect the wire to the turntable rotate left Replace the turntable directional valve coil rotate left directional Test the resistance of valve coil the valve coil See Repair Section Continued from the previous page Exchange the turntable rotate and secondary boom directional valves 2 34 22 before serial number 674 and 2 34 22 before serial number 935 item AF and AK 2 34 22 from serial number 674 to 1733 and Z 34 22N from serial number 935 to 2226 item BF and BK 2 34 22 after serial number 1733 and 2 34 22 after serial number 2226 item CX and CJ Activate the turntable rotate LEFT function Replace defective directional valve function inoperative Continued on the next page CHART 15 Part No 36540 Genie Z 34 22 amp Genie Z 34 22N Section 5 Troubleshooting Flow Charts EEee _ S CHART 15 Continued from the previous page Install a 0 to 5000 PSI 0 to 345 bar pressure gauge at the quick disconnect coupling on the function manifold 2 34 22 before serial number 153 and 234 22 before serial number 304 Move the turntable rotate togg
76. 304 Move 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 Z 34 22 after serial number 152 and Z 34 22N after serial number 303 Hold the function enable toggle switch to either side and move 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 Secondary boom down relief valve specifications Pressure 1600 psi 110 bar 4 Turn the machine off Hold the relief valve and remove the cap Z 34 22 Before serial number 674 item AR From serial number 674 to 1733 item BR After serial number 1733 item CE Z 34 22N Before serial number 935 item AR From serial number 935 to 2226 item BR After serial number 2226 item CE 5 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the relief valve cap AWARNING 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 48 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 7 Repair Procedures How to Adjust the Primary Boom Extend Relief Valve Perform this procedure with the boom in the stowed position 1 Connect a 0 to 3000 psi 0 to 206 bar
77. 4 A 2 28 z ri ee 3 ie a 8 8 8 R8 8 2 E 2 98 868 58 5 TRAVEL ALARM BRAKE RELEASE NC COIL BRAKE RELEASE NO COIL BRAKE RELEASE PRESSURE SWITCH STEER LEFT STEER RIGHT HOUR METER AUXILIARY CONTROL RELAY PROPORTIONAL CONTROL VALVE PLATFORM ROTATE RIGHT JIB BOOM UP PLATFORM ROTATE LEFT JIB BOOM DOWN PLATFORM LEVEL CUT OUT OPTION PLATFORM LEVEL UP COIL PLATFORM LEVEL DOWN COIL BOOM EXTEND BOOM RETRACT ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED 4 gt SETUP ENABLE USE TO THE BATTERY INDICATOR PROFILES PRIMARY BOOM UP PRIMARY BOOM DOWN SECONDARY BOOM UP SECONDARY BOOM DOWN DESCENT ALARM OPTION TURNTABLE ROTATE RIGHT TURNTABLE ROTATE LEFT ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED NOTES ds gt SWITCH SHOWN WITH BOOM EXTENDED gt SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON STEER WHEEL 6 28 Genie 7 34 22 Genie Z 34 22N Part No 36540 First Edition Third Printing Section 6 Schematics E Electrical Schematic CE Models Z 34 22 after serial number 4799 Z 34 22N after serial number 5619 Section 6 Schematics First Edition Third Printing Ground Control Panel Legend Z 34 22 before serial number 153 7 34 22 before serial number 304 A B C QO
78. 4 km h 40 6 8 12 2 m 6 8 sec Drive speeds maximum Z 34 22N stowed position 49 1 drive hubs 2 8 mph 4 5 km h 40 10 12 2 m 10 sec 35 1 drive hubs 3 4 mph 5 5 km h 40 8 sec 12 2 m 8 sec Part No 36540 Genie Z 34 22 amp Genie Z 34 22N Section 7 Repair Procedures First Edition Third Printing PLATFORM CONTROLS Boom Function Speed Controller Adjustments Do not adjust the controllers unless the static battery supply voltage is above 24V DC AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Turn the key switch to platform control and pull out the Emergency Stop button to the on position at both the ground and platform controls 2 Open the platform control box lid and locate the boom function speed controller 0 3 Locate the diode between the black red wire from the boom function speed controller and the white red wire 4 Connect the red lead from a volt meter to the wire connector of the white red wire next to the diode Connect the black lead to ground 5 Turn the boom function speed controller to the CREEP position 6 Set the threshold Press down the foot switch and move the primary boom toggle switch to the pown position Adjust the voltage to 8V DC Turn the threshold trimpot adjustment screw clockw
79. 5 Troubleshooting Flow Charts CHART 5 Continued from the previous page 2 34 22 before serial number 153 and 2 34 22N before serial number 304 Move any boom function toggle switch and check voltage on the wht red 6 wire at TB6 2 34 22 after serial number 152 and Z 34 22N after 303 Hold the function enable toggle switch to either side and move any boom function toggle switch and check voltage on the wht red 6 wire at TB6 Repair open in wht red 3 wire circuit with diode from TB6 to the blk red wire at the boom function speed controller OR replace diode OR troubleshoot ground and platform control functions separately refer to charts 6 and 7 OR consult Genie Industries Service Department 5 24 Genie Z 34 22 amp Genie Z 34 22N First Edition Third Printing Repair open in the wht red 6 wire circuit from TB6 to the boom function proportional Part No 36540 First Edition Third Printing Section 5 Troubleshooting Flow Charts Ground Controls Inoperative Platform Controls Operate Normally Be sure key switch is in the appropriate position Be sure the Emergency Stop buttons are pulled out to the oN position Be sure the battery packs are properly connected and fully charged Check voltage at the red wire on the input side of the ground controls contact of the key switch this wire should originate at the Emergency Stop button 24
80. Any person working on or around a machine must be aware of all known safety hazards Personal safety and the continued safe operation of the machine should be your top priority Read each procedure thoroughly This manual and the decals on the machine use signal words to identify the following Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Red used to indicate the presence of an imminently hazardous situation which if not avoided will result in death or serious injury Orange used to indicate the AWARNING presence of a potentially hazardous situation which if not avoided could result in death or serious injury Yellow with safety alert symbol ACAUTION used to indicate the presence of a potentially hazardous situation which if not avoided may cause minor or moderate injury Workplace Safety other protective clothing if the situation GE Be sure to wear protective eye wear and warrants it such as moving parts free swinging or unsecured components when lifting or placing loads Always wear approved steel toed shoes Be sure to keep sparks flames and Wy lighted tobacco away from flammable and combustible materials like battery gases and engine fuels Always have an approved fire extinguisher within easy reach al Be aware of potential crushing hazards Be sure that al
81. Axle Components 12 1 Drive MOtOF Tar etta Pct n ee Ed ka 7 62 12 2 Drive HUD nasrin ete DNE DR 7 62 Motor Controller 13 1 Motor Controller Z 34 22 after serial number 1733 and Z 34 22N 2226 7 64 Part No 36540 Genie Z 34 22 amp Genie Z 34 22N Xix First Edition Third Printing This page intentionally left blank XX Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 2 Specifications Specifications Machine Specifications Tires and wheels 2 34 22 Stowed dimensions 2 34 22 z 34 22 Tire size 9 14 5 LT Length 18 ft 7 in 18 ft 6 in Tire ply rating Tread 8 Sidewall 6 5 7 m 5 6 m Tire contact area 43 5 sq in 280 sq cm Width 4 ft 10 in 5ft8 in Overall tire diameter 28 in 37 cm 1 5 1 7m z _ Wheel diameter 14 5 in 45 cm Height 6 ft 7 in 6 ft 7 in 2m 2m Wheel width 7 in 18 cm Machine Weight 11 500 Ibs 10 500 Ibs Tires and wheels Z 34 22N 5216 kg 4763 kg Tire size solid rubber 22 x 7 x 17 75 in Ground clearance 5 3 4 in 56 x 18 x 45 cm 14 6 cm 15 2 cm Load range 7600 Ibs 3447 kg Platform dimensions Tire contact area 35 sq in 226 sq cm Length 56 in 142 cm Overall tire diameter 22 56 Width 30 in 76 cm Wheel diameter 17 75 in 45 cm Maxim
82. BRAKE RELEASE JACK CB1 HM HOURMETER REM CH CHASSIS HARNESS J TS51 MH MANIFOLD HARNESS KS1 o RED SP SWITCH PANEL RED WHT 48A e oj CR CONTROL RELAY ip e A2 TRAVEL ALARM OPTION WHT 23A z 4 Li RED ETHER DESCENT ALARM OPTION RED 27A L3 CONTROLLER STATUS LED ORG BLK 15A BLK 7A BLK WHT 8A WHT RED 6A TS63 TS59 de O WE rta Ov ORG 14A GRN BLK 18A GRN WHT 19A TS61 TS57 7 DL GRN BLK 44A D Q tO D j G 558 m Q4 L R GRN 43A RED BLK 2A H 9 P K RED 1A GRN 17A WHT BLK 5A L 7862 WHT 4A TS60 TS55 j L R BLU BLK 11A BLU 10A Z34 22N after serial number 4008 Z34 22N before serial number 4009 Z34 22 after serial number 3308 Z34 22 before serial number 3309 TILT RE TILT Th RED 22D L C RED BLK 28D U WHT 28D_ l 1 BLK 2 BLK BRN CB2 CB2 L3 CB2 L3 ji j BRN 52D T BLK CH BRN 52D BLK CH BRN CH ORG RED 42A BRN CH ORG RED 42A 1 Part No 36540 Genie 2 34 22 amp Genie Z 34 22N First Edition Third Printing Section 6 Schematics Ground Control Panel Wiring Diagram Z 34 22 from serial number 2000 to 3577 Z 34 22N from serial number 2751 to 4260 Section 6 Schematics First Edition Third Printing M Ground Control Panel Wiring Diagram 7 34 22 from serial number 3578 to 4799 7 34 22 from serial numb
83. Box Wiring Diagram Z 34 22 from serial number 1734 to 1834 Z 34 22N from serial number 2227 to 2448 Section 6 Schematics First Edition Third Printing C lM Platform Control Box Wiring Diagram Z 34 22 from serial number 1835 to 2060 Z 34 22N from serial number 2449 to 2870 A B C D E F G H J K L M WHT WHT P SPARE WIRES 2 L1 BLK 1 BLK WHT 1 BLK RED 1 BLU WHT 1 BLU RED 1 TS7 Tei GRN WHT 1 TS9 ORG 1 z 3 ORG BLK 1 OQO A lo z o c gt o 1 gt OF OF O rs J Kg 38 P2 Q QO Q do m 2 o c 22 Osho K TS13 TS10 z L 4 9 f 88 C o TS8 8 3 i BRN gt 5 11 T 210 5 P2 EMERGENCY STOP BUTTON B P3 HORN BUTTON DP1 DRIVE CONTROLLER v BP1 BOOM FUNCTION SPEED CONTROLLER TS1 AUXILIARY POWER TOGGLE SWITCH TS7 PLATFORM ROTATE TOGGLE SWITCH g TS8
84. CO us Brake circuit 16 Solenoid valve poppet Opa Brake circuit 25 30 ft lbs 34 41 Nm 17 Differential sensing valve Differential sensing circuit 10 12 ft Ibs 14 16 Nm 18 Relief valve 3200 psi 220 6 System 22 25 30 ft lbs 34 41 Nm 19 Orifice 0 035 inch 0 89 mm CS uus T2 tank port Added after serial number Z34 22 2894 and Z34 22N 3517 20 Diagnostic fitting CT Pressure test port 21 position 4 way spool valve CU us Secondary boom up down 10 12 ft Ibs 14 16 Nm 22 position 4 way spool valve CV Primary boom up down 10 12 ft Ibs 14 16 Nm 23 Flow regulator valve 1 5 5 7 l min OW Turntable rotate circuit 10 12 ft lbs 14 16 Nm 24 Flow regulator valve 0 8 3 l min CX Jib boom platform rotate circuit 10 12 ft Ibs 14 16 Nm 25 position 4 way spool valve CY aus Turntable rotate left right 10 12 ft Ibs 14 16 Nm 7 44 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 Section 7 Repair Procedures MANIFOLDS First Edition Third Printing Air 7 24 Genie 7
85. CONTACTOR Q4 HG 3DIODES 500A RED 10 Ga DRIVE ONTACTOR SEPEX MOTOR CONTROLLER F1 F2 LEFT SIDE DRIVE MOTOR RED 10 Ga GROUND CONTROLS SIDE BATTERY PACK i AUXILIARY i LIFT PUMP i i i PR4 AUXILIARY LIFT PUMP CONTACTOR Power Cable Diagram Z 34 22 before serial number 1734 Z 34 22N before serial number 2227 RIGHT SIDE DRIVE MOTOR SIDE BATTERY PACK 1 i i I i I GROUND CONTROLS i i 1 i I i AUXILIARY LIFT PUMP PR3 AUXILIARY LIFT PUMP CONTACTOR Power Cable Diagram Z 34 22 from serial number 1734 to 3577 Z 34 22N from serial number 2227 to 4260 Sg 9 o 1 RIGHT SIDE m DRIVE MOTOR Part No 36540 Genie Z 34 22 amp Genie Z 34 22N Section 6 Schematics First Edition Third Printing p Power Cable Diagram Z 34 22 after serial number 3577 Z 34 22N after serial number 4260 LEFT SIDE AMMETER RIGHT SIDE BATTERY PACK T BLK 10 BATTERY PACK WHT 10 AC BATTERY CHARGER PRIMARY BLK 4
86. Continued from the previous page Replace platform level up directional valve coil Exchange the platform level and secondary boom directional valves items AG AL and AE AJ or BG BL and BE BJ or CA and CT Activate the platform level UP function Replace defective directional valve function inoperative function operates Exchange the platform level counterbalance valves items AN and AO or items BN and BO or items CC and CB Activate the platform level UP function Replace defective counterbalance valve function inoperative Continued on the next page 5 74 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 5 Troubleshooting Flow Charts CHART 18 Install a 0 to 3000 psi 0 Check for mechanical to 345 bar pressure restrictions keeping gauge at the quick platform level up disconnect coupling on function from moving the boom function OR replace slave manifold cylinder counterbalance 2 34 22 before serial valves OR consult number 1734 and Genie Industries Service Z 34 22N before serial Department number 2227 Move the platform level up toggle switch and check the pressure 2 34 22 after serial number 1733 and Z 34 22N after serial number 2226 Hold the function enable toggle switch to either side and move the platform level up toggle switch and check the pressure Continued from the previous
87. E i se y AUXILIARY 2 es z PUMP MOTOR N TO amp _ pn ID ELLE qf I 211 xd 1 Seer 1 ii 1 1 1 el f LS S Tol Se lt ite N Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 6 13 Section 6 Schematics Electrical Schematic Z 34 22 before serial number 153 Z 34 22N before serial number 304 C First Edition Third Printing N e LO N 8 m BLU RED 3 ap WHMS I GRIN GROUND DRIVE ENABLE BLU WHT 3 BLK 12 prenre Bla ORG RED 3 a a ORG BLK 1 ORG BLK HOUR METER u Y 5 34 T BREDAMRT RED 47 lg BRAKE RELEASE iu m on d 5 RED lt 5 TRAVEL ALARM opt
88. E te T wy Lh B 9 0 030 4 Ze mm I AUXILIARY PRIMARY ur 234 1891 and Z34N 2547 ET x lt SECONDARY PRIMARY EXTENSION 1 9 L min 7 9 L min STEER CYLINDER CYLINDER CYLINDER CYLINDER 3900 PSI 207 bar TURNTABLE 22 0 082 8 1 ROTATE 0 81 mm 5 BRAKES m T MASTER 641 10 100 CYLINDER 5 9 CU IN MICRON MICRON REV tor tor MESH JH jp 6 HYDRAULIC TANK e oe Fale 3000 PSI 3000 PSI 2500 PSI T d 207 bar 207 bar 172 bar P1 G1 BRAKE PS 611 52 P2 1 L2 TRI TR2 sci 191 sce Pci 31 pop ext 31 DT pe FUNCTION 320051 er a a xt 221 bar XI q oh LS 7 MANIFOLD 1 3 os ICD NI HM at DX 1 2 MEA mE 1600 PSI 1400 PSI 1800 PSI le diss 1 So 000 PSI cs 1100 PSI 110 bar 97 bar 124 bar r1 e 9 207 bar 76 bar 2 3 1 T 4 TOERE SOLA 0 8 GPM 1 5 GPM ev cu ev 8 86 Limin 6 8 L min X MINES 1 5 E Ti 6 43 Genie 2 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 6 Schematics sss Hydraulic Schematic Z 34 22 from serial number 2006 to 2900 Z 34 22N from serial number 2772 to 3532 N M L K J H G F E D JIB BOOM 1 CYLINDER PLATFORM ROTATE
89. ENABLE AG PLATFORM OVERLOAD ALARM m ORGIBLK 3 15 ORG BLK MH ORG BLK SP PLAT LEVEL DOWN L3 CONTROLLER STATUS LED ORGBLCIEA ORG 3 14 ORG MH ORG SP PLAT LEVEL UP BLK 7A L45 PLATFORM OVERLOAD LED EEA WHT 5 BLU RED 3 13 DRIVE ENABLE LIGHT eT BLK 5 BLUMWHT 3 12 BLUWHT cH H FOOTSWITCH TS63 TS59 BLU BLK 3 11 BLU BLK MH BLU BLK SP SEC BOOM DOWN BLU 3 10 BLU MH BLU SP SEC BOOM UP R E BLK RED CR4 BLK RED 3 9 HORN X BLKWHT 3 8 BLK WHT MH 5 BOOM RETRACT ORG 14A 5 4 J BLK 3 BLK MH BLK SP BOOM EXTEND GANBLK 18A ORG GRN WHT 19A TS58 TS61 e WHT RED 3 6 WHT RED MH WHT RED SP BOOM FUNCTION F C GRN BLK 44A D TS58 A 561 TS57 WHT BLK 3 5 WHT BLK MH WHT BLK SP TURN ROTATE RIGHT ORG o WHT 3 4 WHT MH WHT SP TURN ROTATE LEFT GERA RED WHT CR1 RED WHT 3 3 48V RELAY COIL PWR RED BLK 2A RED 1A o RED BLK 3 2 RED BLK MH RED BLK SP PRIMARY BOOM DOWN bore T E RED 3 1 RED MH RED SP PRIMARY BOOM UP 2 5 2 WHT BLK 5A ore E CMM p WHT 4A A D B A D 7860 TS62 TS55 2 Te 6 ov O O O O GRNIWHT 19C 23 7 O ORG RED CH RED 27D GRN WHT CH BLK 22B BLU 10A E E CR1 CR2 CR3 CR4 H 1 3 4 5 6 7 8 12 BRN 52A REDWHT TB3D SWITCH PANEL Q A e BLK RED HORN DESCENT ALARM WIR
90. Genie Industries Service Department 5 90 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 5 Troubleshooting Flow Charts Jib Boom Down Function Inoperative Be sure key switch is in the appropriate position Be sure the Emergency Stop buttons are pulled out to the oN position Be sure the battery packs are properly connected and fully charged Turn key switch to ground controls and pull both Emergency Stop buttons out to the ON position 2 34 22 before serial number 153 and Z34 22N before serial number 304 Move the jib toggle switch 7516 in the DOWN direction and check the voltage on the wht red 6 wire at the boom function proportional valve coil item AU 27 34 22 after serial number 152 and 734 22 after serial number 303 Hold the function enable toggle switch to either side and move the jib toggle switch TS16 in the DOWN direction and check the voltage on the wht red 6 wire at the boom function proportional valve coil item AU or BU 27 34 22 after serial number 1733 and 734 22 after serial number 2226 Hold the function enable toggle switch to either side and move the jib toggle switch TS58 in the DOWN direction and check the voltage on the wht red 6 wire at the boom function proportional valve coil item CH 20V or more Continued on the next page 2 34 22 before serial number 153 and 234 22 before serial num
91. I X a Normally open poppet valve Part No 36540 Genie Z 34 22 amp Genie Z 34 22N Section 6 Schematics First Edition Second Printing ee This page intentionally left blank 6 12 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Electrical Schematic 7 34 22 before serial number 153 7 34 22 before serial number 304 Section 6 Schematics 8 age 2 are im gt a tc E cr 2 tc 5 9 W e og Ee 1 E329 gom 9 i hogg os a 9 N es g 3 5 UP B 4 lh E RED 1 j PRIMARY BOOM UP P
92. ILE TS12 B P3 Lo NO Li Q d 3 B TS13 TS11 j feg ooy FO NC GPH PAK TNG TS10 C TS7 TS9 RAI ado Caste TS8 BCI RED 1 BRN GRN BLK RED m eiu edis cms en 1 2 5 2 1 x T LABEL DESCRIPTION P2 EMERGENCY STOP BUTTON P3 HORN BUTTON L R DP1 DRIVE CONTROLLER 2 BP1 BOOM FUNCTION SPEED CONTROLLER 1 2 3 4 5 6 7 8 9 10 TS1 AUXILIARY TOGGLE SWITCH 6 TS7 PLATFORM ROTATE TOGGLE SWITCH Ju eee TERMES TS10 SECONDARY BOOM UP DOWN TOGGLE SWITCH TS11 PRIMARY BOOM UP DOWN TOGGLE SWITCH TS12 TURNTABLE ROTATE TOGGLE SWITCH TS13 EXTEND RETRACT TOGLE SWITCH TS15 DRIVE ENABLE TOGGLE SWITCH DRIVE ENABLE LIGHT BCI BATTERY CHARGE INDICATOR 7 HA A a eh qu e ha a CENT I ee E w m lo m TERE RE lgiseeeee E FEE IRE Ge B ES g 2 a BE E E IS EJE Se PA BS espt m Tes seseg 38358682802 2 208 5 o X I p m E x r ir m 2 gsm ce e aleg pal el el Bele al REMOVE THIS WIRE WHEN LOAD SENSE OPTION IS REQUIRED REMOVE JUMPER JP1 FOR CE VERSION Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 6 37 First Edition Third Printing Section 6 Schematics Platform Control
93. Instruments 13508010 1 BPA asi Rotational Controller 36557 OEM Controls RS10T4381 1 CB Circuit breaker 375785 45 700 IG1 P10 1 RE Relay 24V DC 426106 Potter and Brumfield K10P 11D15 24 3 nune Relay SPST 24V DC 56302 Potter and Brumfield VF4 15H11 CO5 9 CR esie Relay DPDT 24V DC 36354 QRmmtOh erret 1 Diode Diode 6 amp 200 45782 Motorola MOTMR7B2 36 DPA Joystick controller 56274 OEM Controls MS6M11498 1 FB 2e Flashing beacon 20189 ECCO Electronic Controls 6400 1 a Fuse 500 amp 43179 22 ANN 500 1 F2 Fuse 100 amp 36355 LAS ANN 100 2 Foot switch 13482 Linemaster Switch Corp 0632 9 hdd 1 bbs Alarm Warble tone
94. RD POT LOW a 8 A 1 amp 5 lt C31REV WH BK 1 5 C49 5 WH BK REVERSE 1 a 1 4 4 C30FWD WH C1B 4 C494 WH FORWARD B oz E i DIODE RETURN 9 lt i se 5 R42BAT OR RD 48V INPUT i 5 g 1 2 E 7 4 Es 8 Z 3 i 5 E z 2 xs i 8 5 n WH 4 9 3 a 5 e 50 2 gt B oe oe ee 4 PRIMARY 9 os LIFT PUMP E Be pose y a 3 z iage 4 AUXILIARY ri LIFT PUMP 8 4 Ir Se 7 n C48 1 P182BAT RD u a lt E 2 gt 1 3 55 Ze N lt N co Part No 36540 e gt ADD D40 ONLY IF UNIT HAS L4 AND L48 Genie Z 34 22 amp Genie Z 34 22N gt SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON STEER WHEEL 4 ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED gt SWITCH SHOWN WITH BOOM EXTENDED 6 27 Section 6 Schematics First Edition Third Printing Electrical Schematic CE Models 7 34 22 after serial number 4799 7 34 22 after serial number 5619 C C29JSH RD WH C29JSH RD WH
95. RD MH HORN CR10A PLAT LEVEL CUTOUT CE ONLY CR10B PLAT LEVEL CUTOUT CE ONLY OR RD 42D BK RD C3B 9 RD C49 1 RD WH 48D OR MH OR BK MH REF l 1 CRS CR10A RD BK C49 2 11 1 1 SS 7 1 I OR RD 16A BR 52D MANIFOLD HARNESS OR 4A OR BK 15A I MH pe Soe eee TEE OEEO EEE 48 000 11 2 8 CHASSIS f HARNESS H OR BK C4B 3 15 OR BK CR10B OR BK SP PLAT LEVEL DOWN 49 i i i 500000 me OR C4B 2 14 OR CRIOA OR SP PLAT LEVEL UP i i PLATFORM LEVEL CUTOUT CE VERSION ONLY Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 6 35 First Edition Third Printing Section 6 Schematics E Ground Control Terminal Strip Wiring Diagram Z 34 22 after serial number 4799 7 34 22 after serial number 5619 5 oz GRN WHT 45 1 BLU RED 39 1 BLU WHT 48 1 BLK RED 35 1 BLK WHT 34 1 BLK 33 1 BRN ES RED JIB E CR5 DESCRIPTION L V 1 B C I OPTION EMERGENCY STOP BUTTON JIB BOOM UP DOWN TOGGLE SWITCH AUXILIARY POWER TOGGLE SWITCH DRIVE ENABLE TOGGLE SWITCH PLATFORM ROTATE TOGGLE SWITCH DRIVE ENABLE LIGHT BOOM SPEED CONTROLLER TURNTABLE ROTATE TOGGLE SWITCH SECONDARY BOOM TOGGLE SWITCH PRIMARY BOOM TOGGLE SWITCH EXTEND RETRACT TOGGLE SWITCH PLATFORM LEVEL TOGGLE SWITCH BAT
96. RDK WH 1 al C7P 2_ 2 WH C7B 2 RD 4 RD BK BRN TILT SENSOR 8 i NA m HE 3 8 Sag BASE CONTROL na 2 BOX GROUND 4 j oS 29 a ll sy COHANBKIAD Cabo i E g 8 Y oO e E t 06 1 AUXILIARY LIFT E s C49 1 R27AUX RD D PUMP PAS a 8 CI33PLABURD 2 1 15 i E gt See E 2 5 ee ee es pe M ao i Y_P22BAT BK 7 1 8 C49 11 C19LPE GRWH 81 8 4 PRIMARY LIFT PUMP o CONTACTOR RELAY 1 acon E 1 1 i a S a i 5 5 al 4 RISLPE GR WH PRIMARY LIFT N je gi PUMP PR2 T 4 y E zao 222 a 2 z SER 5 A ai o 0 8 3 C9HRN BK RD 85 8 BRN HORN E e 8 to 8 r RELAY 8 we 5 HORN i 5 8 2 RD n P22LS 10 1 7 2 LS1 EXT RET 9 22 l es 2 J2 BK 2 7 MDE lt i z a ES C52 1 8 E C114 WHS 5 E C52 2 WH 8 C11 3 BK 6 LS2 PRI UP DWN 5 9 aa 5 J LS4 SEC UP DWN CONTROLLER STATUS 29 az LED L3 40 C49 7 CI78CSL a ix CHASSIS GROUND o 9 NA 5 Mpt C49 2 CABBRK RDIBK BRAKE RELEASE 8 8 RELAY CRS X C182PWR DRIVE g eform 7 7 CONTACTOR a 5 8 g C4
97. RED 1 27 RED SP AUXILIARY PUMP SELECT 26 LIFT LOCKOUT 25 BATTERY LIGHT 24 TRACTION CONTROL OPTION 2 23 KEYSWITCH POWER REDWHT TILT RED TILT WHT 2 23 WHT SP KEYSWITCH POWER 23422 ater soral number 3308 WHT 7 BLK 2 22 BLK CR4 BLK SP 24V TO PLATFORM 36 7837 GRNWHT CR3 19 GRNWHT MH LIFT PUMP M WHT eLK SP GRNAWHT 3 19 GRNWHT SP LIFT PUMP GRN BLK 8 18 GRN BLK SP PLAT ROTATE RIGHT GRN 3 17 GRN SP PLAT ROTATE LEFT RED 5 ORG RED 3 16 ORG RED CR5 DRIVE ENABLE ORG BLK 3 15 ORG BLK MH ORG BLK SP PLAT LEVEL DOWN ORG 3 14 ORG MH ORG SP PLAT LEVEL UP WHT 5 BLU RED 3 13 DRIVE ENABLE LIGHT BLK 5 BLUMHT 3 12 BLUWHT CH FOOTSWITCH BLUIBLK 3 11 BLU BLK MH BLU BLK SP SEC BOOM DOWN BLU 3 10 BLU MH BLU SP SEC BOOM UP BLK RED CR4 BLK RED 3 9 HORN BLK WHT 3 BLKWHT MH BLK WHT SP BOOM RETRACT BLK 3 7 BLKMH BLK SP BOOM EXTEND WHT RED 3 6 WHT RED MH WHT RED SP BOOM FUNCTION F C WHT BLK 3 5 WHT BLK MH WHT BLK SP TURN ROTATE RIGHT WHT 3 4 WHT MH WHT SP TURN ROTATE LEFT RED WHT CR1 RED WHT 8 3 48V RELAY COIL PWR RED BLK 3 2 RED BLK MH RED BLK SP PRIMARY BOOM DOWN RED 3 1 RED MH RED SP PRIMARY BOOM UP D B A SEE OPTIONAL WIRING GRN WHT 19C ORG RED CH RED 27D GRRAWHTOH scias RI cR2 F BRN 52A RED WHT TB3D E BLK RED HORN ORG RED 42D RED CH Bremeno RED WHT 48C ORG MH ORG BLK MH cm emoe RED
98. Remove all rings watches zero Q and other jewelry This procedure covers fundamental relay testing and does not specifically apply to all varieties of relays 1 Turn the key switch to the position and 4 85 87 87a O 2 Label and then disconnect all the wiring from the relay to be tested 3 Connect the leads from an ohmmeter to each terminal combination and check for continuity 0 Terminals 85 86 represent the coil and 86 30 should not be tested in any other combination Relay Schematic Test Desired result terminal 85 to 86 85 to 950 87 terminal 87 to 87a amp 30 no continuity 87a infinite Q 86 85 terminal 87a to 30 continuity 30 zero Terminal Numbers Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 7 35 Section 7 Repair Procedures First Edition Third Printing r d d H u i GROUND CONTROLS 6 2 6 3 Toggle Switches Wago Components See 1 3 Toggle Switches How to Remove a Wago Component AWARNING Electrocution burn hazard Contact with electrically charged circuits may cause death or serious injury Remove all rings watches and other jewelry Wago tools are available from the Genie Service Parts Department Genie part number 33996 1 Labelthe wiring from the component to be removed 2 Push the Wago tool firmly into the slot to release the wire from the componen
99. Replace the 500A fuse F1 OR replace the PR3 contacts OR replace PR3 Repair open in the red power supply wire circuit from key switch to the auxiliary pump toggle switch Repair open in the red wire circuit from the auxiliary pump toggle switch to TB27 OR replace toggle switch Repair open in the red 27 wire from toggle switch to control relay Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 5 Troubleshooting Flow Charts Continued from the previous page Check continuity of the Repair open in the brn brn ground wire from the ground wire circuit from control relay to ground control relay to ground continuity Hold the auxiliary pump Replace control relay toggle switch and move any boom function toggle switch Check voltage at the control relay output terminal Repair open in the red wire from control relay to 2 34 22 before serial number 1734 and 2 34 22 before serial number 2227 PR4 2 34 22 after serial number 1733 and 2 34 22 after serial number 2226 PR3 CHART 3 Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 5 19 Section 5 Troubleshooting Flow Charts First Edition Third Printing Chart 4 All Functions Inoperative Power Unit Starts and Runs Be sure the circuit breaker and fuse are not tripped or blown Be sure the battery packs are properly connected and fully charged
100. Section item AB or BB or CR OR repair or replace cylinder s or cylinder s counterbalance valve s OR function manifold could have an internal defect Consult Genie Industries Service Department Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 5 49 Section 5 Troubleshooting Flow Charts First Edition Third Printing Chart 13 Primary Boom Extend Function inoperative Be sure key switch is in the appropriate position Be sure the Emergency Stop buttons are pulled out to the on position Be sure the battery packs are properly connected and fully charged Turn key switch to ground controls and pull both Emergency Stop buttons out to the ON position 2 34 22 before serial number 153 and Z34 22N before serial number 304 Move the primary boom extend retract toggle switch TS13 in the EXTEND direction and check voltage on the wht red 6 wire at the boom function proportional valve coil item AU or BU or CH Z 34 22 from serial number 153 to 1733 and Z 34 22N from serial number 304 to 2226 Hold the function enable toggle switch to either side and move the primary boom extend retract toggle switch TS13 in the EXTEND direction and check voltage on the wht red 6 wire at the boom function proportional valve coil item AU or BU or CH Z 34 22 after serial number 1733 and Z 34 22N after serial number 2226 Hold the function enable toggle Switch to either side and move the pri
101. Section 4 Scheduled Maintenance Procedures First Edition Third Printing TABLE A PROCEDURES Drive Enable Limit Switch 1 With the boom in the stowed position visually inspect the drive enable limit switch for the following Broken or missing roller or arm Missing fasteners Loose wiring 2 Turn the key switch to platform control and pull out the Emergency Stop button to the oN position at both the ground and platform controls 3 Atthe platform controls rotate the turntable to the left until the primary boom is past the left non steer wheel Result The drive enable indicator light should be oN 4 Move the drive control handle off center Result The drive function should not operate 5 Move and hold the drive enable toggle switch to either side and slowly move the drive control handle off center Result The drive function should operate 6 Manually activate the drive enable limit switch Result The drive enable limit switch roller should move freely and spring return to center A distinct click should be felt and heard 3 swing chassis limit switch cam drive enable limit switch LS3 drive chassis a ae 4 10 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 4 Scheduled Maintenance Procedures p M M H il
102. TABLE A PROCEDURES A 10 A 11 Test the Lift Drive Select Switch Perform 30 Day 50 hour Service if equipped The 30 day maintenance procedure is a onetime sequence of procedures to be performed after the first 30 days or 50 hours of usage After this interval refer to the maintenance tables for 2 Press down the foot switch and move the drive continued scheduled maintenance control handle off center 1 Move the lift drive select switch to the lift position 1 Performthefollowing maintenance procedures Result No drive functions should operate e 3 Inspect Tires and Wheels 3 Activate each boom function toggle switch including lug nut torque O Result All boom functions should operate 20 Replacethe Hydraulic Tank ReturnFilter 4 the lift drive select switch to the drive e C2 Checicthe Tumable Rotation positon Bearing Bolts 5 Press down the foot switch and activate each boom function toggle switch Result No boom functions should operate Move the drive control handle off center Result The drive functions should operate Part No 36540 Genie 7 34 22 amp Genie Z 34 22N 4 11 Section 4 Scheduled Maintenance Procedures First Edition Third Printing Table B Procedures B 1 5 Remove the battery vent caps and check the specific gravity of each battery cell with Check the Batteries hyaromet r Proper battery condition is essential to good Result If any battery
103. TS13 TS10 8 D B foo 64 GE O O p PS TS8 Woe a E T Gp 5 4 EE 2 w 3 8 wv BRN RED DP1 LOR 1 3 6 7 8 9110 ND NOTES 3p No EE CER al R RBS 2 o ja pi gt 5 f Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 6 39 First Edition Third Printing Section 6 Schematics Platform Control Box Wiring Diagram 7 34 22 from serial number 2061 to 3577 7 34 22 from serial number 2871 to 4260 First Edition Third Printing Section 6 Schematics l Platform Control Box Wiring Diagram Z 34 22 after serial number 3577 7 34 22 after serial number 4260 WHT WHT 1 SPARE WIRES n TS15 f gt 5 O BLK 2 Y BLK WHT 1 lt
104. WH BK HOUR METER amp 8 C27AUX RD C1B 1 RD AUX Ty ON I 1 c Sa E 55 8 FN i 8 i 5 E amp IE ul Numi f 1 Se S i PN E38 e 8 AUXILIARY CONTROL g gt 2 p B RD eje 4 RELAY o 5 i g 5 8 5 E z A BW S ccc Lic ccc c CE Jesi Bio jOR RD 9 1 is i JX P 4 wv is m o B i WH 7 C19LPE C4B 7 gt P i C19LPE GRWH 1 8 1 C3P 6 CEMFV WH RD C3B 6 E WH RD PROPORTIONAL a CONTROL VALVE ac cA 3 z gt H 5285 5 E roro i 1 1 1 1 1 i 1 1 1 1 1 i 1 i 1 1 1 1 1 1 1 1 1 i 1 1 i i PLATFORM ROTATE RIGHT JIB BOOM UP I PLATFORM ROTATE LEFT JIB BOOM DOWN ee ee i 9 1 C2P 5 C43JU GR C2B 5 oe C2P 6 C44JD GR BK 2 61 car3 C44JD IA 1 1 a 1 47 4 C43JU BK d RIGHT a 1 gt n 1 z 4 5 i 47 1 C18PRLOR 2 og g my Ex x m gt Td 55 5 m ee ee ees Bo E 47 2 C17PRR BL JA 8 9 ER 1 6 PLATFORMLE
105. WHT RED WHT 1 6 22 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition First Printing Section 6 Schematics Electrical Schematic Z 34 22 from serial number 2061 to 3577 Z 34 22N from serial number 2871 to 4260 Section 6 Schematics First Edition Third Printing SSS SS SSS Electrical Schematic Z 34 22 from serial number 3578 to 4799 Z 34 22N from serial number 4261 to 5619 A B C D E F G H J K L M N BLWH 1 TB134 ES P2 1 BLK 2 J Ci WHT FS WHT RED 134B eL 4 54 E ORG RED 1 U33 lt a lt A a 9 1518 E e KS1 2 v Pi PLT BLK 22 TB22 gt 8 lt lt EA 10 8l see COMME e HORN 5 7 V BEL L45 D GND RED BLU RED 1 1 ORG RED CR20 i ORG RED WHT 30 TES WHT 1 WHT 1 WHT BLK 31 I il WHT BLK 1 WHT BLK 1 e BLUMWHT 12 RED WHT 29 7829 REDMWHT 1 RED WHT 1 ie 3 WHT RED 32 TB
106. a schedule daily hourly quarterly annual and two year To account for repeated procedures the Maintenance Tables and the Maintenance Inspection Heport have been divided into four subsections A B C D Use the following chart to determine which group s of procedures are required to perform a scheduled inspection Inspection Table or Checklist Daily A Hourly and Quarterly A B Annual A B C Two year A B C D Maintenance Tables The maintenance tables contained in this section provide summary information on the specific physical requirements for each inspection Complete step by step instructions for each scheduled maintenance procedure are provided in section 4 Scheduled Maintenance Procedures Maintenance Inspection Report The maintenance inspection report contains checklists for each type of scheduled inspection Make copies of the Maintenance Inspection Report to use for each inspection Maintain completed forms for a minimum of 4 years or in compliance with employer jobsite and govermental regulations and requirements Part No 36540 Genie 2 34 22 amp Genie Z 34 22N 3 1 Section Scheduled Maintenance Inspections First Edition Third Printing Maintenance Tables Tools are New parts engine engine service required required required required suggested A 1 Inspect the Operator s and Safety Manuals A 2 Inspect the Decals and Placards A 3 Inspect for Damage and Loose or Missing Par
107. add oil until the oil level is even with the bottom of the side plug hole TABLE B PROCEDURES 4 Apply pipe thread sealant to the plugs and install the plugs into the hub 5 Repeatthis procedure for each drive hub Drive Hub Oil Capacity before serial number 1734 49 1 and 35 1 models 17 fluid ounces 0 5 liters after serial number 1733 47 1 models 25 6 fluid ounces 0 76 liters Type SAE 90 multipurpose hypoid gear oil API service classification GL5 Part No 36540 Genie Z 34 22 amp Genie Z 34 22N Section 4 Scheduled Maintenance Procedures First Edition Third Printing TABLE B PROCEDURES B 6 Test the Key Switch Proper key switch action and response is essential to safe machine operation The machine can be operated from the ground or platform controls and the activation of one or the other is accomplished with the key switch Failure of the key switch to activate the appropriate control panel could cause a hazardous operating situation 1 Pull out the Emergency Stop button to the oN position at both the ground and platform controls 2 Turn the key switch to platform control 3 Check the machine functions from the ground controls Result The machine functions should not operate 4 Turn the key switch to ground control 5 Check the machine functions from the platform controls Q Result The machine functions should not operate 6 Turn the key switch to the orr posit
108. air line to platform option the air line must be disconnected from the platform before removal 3 Place blocks under the platform for support and carefully lower the platform on the blocks 4 Remove the platform mounting fasteners and remove the platform Component damage hazard CAUTION Platform can be damaged if the fasteners are overtightened 2 2 Platform Leveling Slave Cylinder The slave cylinder and the platform rotator are the two primary supports for the platform The slave cylinder keeps the platform level through the entire range of primary boom motion It operates in a closed circuit hydraulic loop with the master cylinder The slave cylinder is equipped with counterbalance valves to prevent platform movement in the event of a hydraulic line failure How to Remove the Slave Cylinder Before cylinder removal is considered bleed the slave cylinder to be sure there is no air in the closed loop hydraulic circuit When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Extend the boom until the slave cylinder barrel end pivot pin is accessible 2 Raise the boom slightly and place blocks under the platform for support Lower the boom until the platform is resting on the blocks 3 Remove the pin retaining fastener from the rod end
109. and castle nut Always replace the cotter pin with a new one when removing the castle nut 6 Pull the hub off the yoke spindle The washer and outer bearing should fall loose from the hub 7 Place the hub on a flat surface and gently pry the bearing seal out of the hub Remove the inner bearing When removing a bearing always use a new inner bearing seal How to Install the Hub and Bearings When replacing a wheel bearing both the inner and outer bearings including the pressed in races must be replaced 1 Be sure that both bearings are packed with grease 2 Place the large inner bearing into the rear of the hub 3 Press the inner bearing seal evenly into the hub until it is flush 4 Apply a small amount of grease onto the yoke spindle 5 Slide the hub onto the yoke spindle CAUTION Component damage hazard Damage to the lip of the seal may occur if excessive force is applied Place the outer bearing into the hub Install the washer and castle nut Tighten the castle nut to 35 ft Ibs 47 Nm o N O Loosen the castle nut and tighten to 8 ft lbs 11 Nm 10 Install a new cotter pin Bend the cotter pin to lock it Always replace the cotter pin with a new one when installing the castle nut 11 Install the dust cap Install the tire and wheel assembly Torque the wheel lug nuts to 125 ft lbs 169 5 Nm Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Print
110. and should not be tested in any other combination Bubble number represents the terminal number Test Desired result terminal 7 to 8 640 to 6500 terminal 1 to 2 3 4 amp 6 no continuity infinite terminal 2 to 3 4 amp 5 no continuity infinite terminal 3 to 6 no continuity infinite terminal 2 to 6 continuity zero terminal 1 to 5 continuity infinite 4 Connect 24V DC to terminal 8 and a ground wire to terminal 7 then test the following terminal combinations Test Desired result terminal 1 to 2 4 5 amp 6 no continuity infinite terminal 2 to 3 5 amp 6 no continuity infinite terminal 1 to 3 continuity zero terminal 2 to 4 continuity zero Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 7 Repair Procedures How to Test a Single Pole Double Throw Relay Relays used for single function switching are single pole double throw SPDT relays GROUND CONTROLS 4 Connect24V DC to terminal 85 and a ground wire to terminal 86 Test the following terminal combinations Test Desired result terminal 87a to 87 amp 30 no continuity AWARNING Electrocution burn hazard Contact infinite Q with electrically charged circuits could cause death or serious terminal 87 to 30 continuity injury
111. as a visual reference for use when crossing the test line 6 Bring the machine to maximum drive speed before reaching the test line Release the drive joystick when your reference point on the machine crosses the test line 7 Measure the distance between the test line and your machine reference point Braking paved surface Stopping distance 3 to 4 ft 0 9 to 1 2 m The brakes must be able to hold the machine on any slope it is able to climb Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 4 Scheduled Maintenance Procedures B 14 Test the Drive Speed Stowed Position Proper drive function movement is 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 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 Lowerthe boom into the stowed position 3 Turn the key switch to platform control and pull out the Emergency Stop button to the position at both the ground and platform controls 4 Move the lift drive switch to the prive position if equipped 5 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the
112. be damaged if they are kinked or pinched 13 Remove all of the hose and cable clamps from the underside of the primary boom 14 Remove the turntable end cover 15 Remove the extension boom drive limit switch from the side of the primary boom at the pivot end Do not disconnect the wiring 16 Pull all of the electrical cables and hydraulic hoses out of the plastic cable track 17 Remove the pin retaining fastener from the master cylinder rod end pivot pin Use a soft metal drift to remove the pin Pull the cylinder back and secure it from moving 18 Tag disconnect and plug the extension 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 19 Attach an overhead 5 ton crane to the center point of the boom PRIMARY BOOM COMPONENTS 20 Attach a similar lifting device to the lift cylinder 21 Place support blocks under the cylinder across the secondary boom 22 Remove the pin retaining fastener from the boom lift cylinder rod end pivot pin Use a soft metal drift to remove the pin ACAUTION Crushing hazard The boom lift cylinder will fall unless it is properly supported 23 Lower the rod end of the lift cylinder onto support blocks 24 Remove the pin retaining fastener from the primary boom pi
113. black no continuity the platform toe board infinite 2 Do not press down the foot switch Connect the ed to white no continuity leads from an ohmmeter or continuity tester to infinite Q each wire combination listed below and check black to white continuity for continuity zero Q Test Desired result red to black continuity 2 zero red to white no continuity FOOT SWITCH infinite Q N O N C black to white no continuity A 2 D infinite Q 1 J red black white brown Do not use the color of the 5 2 round connector as a guide for these tests Use the actual wire color to identify which connector to use for testing Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 7 9 Section 7 Repair Procedures First Edition Third Printing PLATFORM CONTROLS 1 3 Toggle Switches Toggle switches used for single function switching are single pole double throw SPDT switches Dual function switching requires a double pole double throw DPDT switch How to Test a Toggle Switch Continuity is the equivalent of 0 to 3 ohms A simple continuity tester may not accurately test the Switch This procedure covers fundamental switch testing and does not specifically apply to all varieties of toggle switches 1 Turn the key switch to the orr position Tag and disconnect all wiring from the toggle switch to be tested 2 Connect the leads of an ohmmeter to the Switch terminals in the following combinati
114. boom is raised past the drive speed limit switch Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 4 5 Section 4 Scheduled Maintenance Procedures First Edition Third Printing TABLE A PROCEDURES Z 34 22N after serial number 303 and Z 34 22 and after serial number 152 1 Turn the key switch to ground controls and pull out the Emergency Stop button to the position at both the ground and platform controls Result Beacon if equipped should flash 2 Do not hold the function enable switch to either side Attempt to activate each boom and platform function toggle switch Result All boom and platform functions should not operate 3 Hold the function enable switch to either side and activate each boom and platform function toggle switch Result All machine functions should operate through a full cycle The descent alarm if equipped should sound while the boom is lowering Machines equipped with Platform Level Control Disable Function The platform level toggle switch will not operate when the boom is raised past the drive speed limit switch 4 Push in the Emergency Stop button to the position Result No function should operate The machine should stop Turn the key switch to platform control and pull out the Emergency Stop button to the on position at both the ground and the platform controls Result Beacon if equipped should flash Press down the foot switch and
115. brake release functions should be operating normally If they do not begin troubleshooting from beginning of chart 5 118 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 5 Troubleshooting Flow Charts CHART 30 Check continuity from Repair open in brn ee n the the brake release valve ground wire circuit from page cartridge to the ground the function manifold to bolt inside the ground the ground bolt inside control box the ground control box continuity Disconnect the wires from each of the valve coils arid check the ee defective valve resistance of the valve 9n coils See Repair Section Consult Genie Industries Service Department Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 5 119 Section 5 Troubleshooting Flow Charts First Edition Third Printing Chart 31 Drive Forward Function inoperative Z 34 22 before serial number 1734 and Z 34 22N before serial number 2227 Be sure key switch is in the appropriate position Be sure the Emergency Stop buttons are pulled out to the on position Be sure the battery packs are properly connected and fully charged Turn key switch to platform controls and pull both Emergency Stop buttons out to the ON position Press down the footswitch and move the drive controller in the FORWARD direction and check voltage on wht blk 31 wire on forward contactor
116. check voltage at the positive cable on output side of PR1 Block the steer wheels and raise the machine so the drive tires are off the ground Place blocks under the drive chassis for support Disconnect wht wire on forward reverse contactor PR2 With key switch turned to platform controls and both Emergency Stop buttons pulled out to the ON position press down the foot switch and move the drive controller to full FORWARD direction and try to rotate the drive tires by hand Note this will require 2 people tires move Continued on the next page 48V or more Replace 500A F1 Repair open in positive cable from output terminal of 500A fuse F1 to input side of PR1 Repair open in wire circuit from terminal 1 on the motor controller to PR1 OR repair open in the ground wire circuit from PR1 to ground OR replace PR1 contacts OR replace PR1 OR consult Genie Industries Service Department Go to Chart 28A Brake Function Inoperative CHART 28 Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 5 101 Section 5 Troubleshooting Flow Charts FEIERT LL LE ee CHART 28 Continued from the previous page Connect wht wire to less forward reverse than contactor PR2 Press 48V down the foot switch and move the drive controller to full FORWARD direction and check voltage at positive cable on output side of PR1 48V or more Continued on the next page First Edition
117. cover 1 Turn the key switch to ground control and pull out the Emergency Stop buttons to the oN position Result The flashing beacon should be on and flashing 2 Z 34 22 before serial number 153 and Z 34 22N before serial number 304 Move the primary boom toggle switch to the down position hold for a moment and then release it Z 34 22 after serial number 152 and Z 34 22N after serial number 303 Hold the function enable toggle switch to either side Move the primary boom toggle switch to the down position hold for a moment and then release it TABLE B PROCEDURES 3 Z 34 22 before serial number 153 and Z 34 22N before serial number 304 Move the secondary boom toggle switch to the DOWN position hold for a moment and then release it Z 34 22 after serial number 152 and Z 34 22N after serial number 303 Hold the function enable toggle switch to either side Move the secondary boom toggle switch to the pown position hold for a moment and then release it Z 34 22 before serial number 153 and Z 34 22N before serial number 304 Move the jib boom toggle switch to the Down position hold for a moment and then release it Z 34 22 after serial number 152 and Z 34 22N after serial number 303 Hold the function enable toggle switch to either side Move the jib boom toggle switch to the DOWN position hold for a moment and then release it Result The descent alarm should sound when each control toggle switch is held do
118. cover 2 Remove the tank mounting fasteners Remove the tank from the power unit 3 Completely drain the tank into a suitable container See capacity specifications 4 Remove the suction strainer and the magnet Clean the tank with mild solvent 5 Clean up any oil that may have spilled Hydraulic Oil Specifications Hydraulic oil type Dexron equivalent Z 34 22 before serial number 809 and Z 34 22N before serial number 1116 Hydraulic tank capacity 5 gallons 18 9 liters Hydraulic system 7 gallons including tank 26 5 liters Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 7 Repair Procedures How to Remove the Hydraulic Tank Z 34 22 after serial number 808 and Z 34 22N after serial number 1115 1 Open the tank side turntable cover 2 Close the hydraulic shutoff valve located at the hydraulic tank Component damage hazard The CAUTION machine must not be operated with the hydraulic tank shut off valve in the cLosep position or component damage will occur If the tank valve is closed remove the key from the key switch and tag the machine to inform personnel of the condition 3 Place a suitable container under the hydraulic tank See capacity specifications 4 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 conne
119. down the foot switch and move any boom function toggle switch and check voltage at the red wire on the boom function speed controller 24V With the boom function less speed controller setto 9 than press down the foot 20V switch and move any boom function toggle switch and check voltage at the blk red wire on boom function speed controller 20V or more Continued on the next page Test the foot switch See good Repair Section bad Replace the foot switch Press down the foot switch and check voltage at the terminal 7 on the drive controller Replace the drive controller or consult Genie Industries Service Department Repair open in power supply circuit to boom function speed controller from each individual boom function toggle switch OR consult Genie Industries Service Department Adjust boom function speed controller see Repair Section OR replace boom function speed controller OR consult Genie Industries Service Department First Edition Third Printing 24V Repair open in wht FS wire circuit from foot switch to the center terminal of TS1 to terminal 6 on the drive controller Repair open in red wire circuit from terminal 6 to terminal 7 on the drive controller to each function toggle switch Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 5 Troubleshooting Flow Charts CHART 8 Pre
120. each inspection procedure is completed Use the maintenance tables in this section and the step by step procedures in section 4 to learn how to perform these inspections e 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 Y yes acceptable N no remove from service R repaired Comments Checklist A Y N R B 9 Platform leveling Refer to Table A B 10 Horn A 1 Operator s and Safety manuals A 2 Decals and placards A 3 Damage and loose or missing parts A 4 Hydraulic oil level A 5 Hydraulic leaks A 6 Platform and ground controls A 7 Auxiliary power A 8 Tilt sensor A 9 Limit switches A 10 Lift Drive select switch if equipped A 11 30 Day 50 Hour Service ChecklistB YNR Refer to Table B B 1 Batteries B 2 Electrical wiring B 3 Tires and wheels B 4 Brake configuration B 5 Drive hub oil level B 6 Key switch B 7 Emergency stop B 8 Ground control override B 11 Foot switch B 12 Drive enable system B 13 Drive brakes B 14 Drive speed stowed B 15 Drive speed raised B 16 Alarm package if equipped B 17 Turntable stop B 18 Electrical contactors B 19 Hydraulic oil analysis Perform quarterly or every 250 hours B 20 Hydraulic return filter Checklis
121. 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 disconnect the battery packs from the machine 2 Tagand disconnect all power cables from the motor controller Electrocution burn hazard Contact AWARNING with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 3 Press the release tab on the motor controller harness connector and remove the motor controller harness connector from the motor controller 4 Set an ohmmeter to diode test mode 5 Connect the leads from an ohmmeter to test each motor controller terminal combination listed below and check the forward reverse bias diode test Result All desired results must be within the specified range If any test has a result not within the specified range replace the motor controller Forward Bias Test Desired result Positive Lead Negative Lead M B 0 4 to 0 45 B 0 4 to 0 45 F1 B 0 45 to 0 5 F2 B 0 45 to 0 5 B
122. illustrations to determine that all decals and placards are in place 2 Inspect all decals for legibility and damage Replace any damaged or illegible decal immediately Contact your authorized Genie distributor or Genie Industries if replacement decals are needed 4 2 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 4 Scheduled Maintenance Procedures A 3 Inspect for Damage and Loose or Missing Parts Daily machine condition inspections are essential to safe machine operation and good machine performance Failure to locate and repair damage and discover loose or missing parts may result in an unsafe operating condition 1 Inspect the entire machine for damage and improperly installed or missing parts including Electrical components wiring and electrical cables Hydraulic power units reservoir hoses fittings cylinders and manifolds Drive and turntable motors and drive hubs Boom wear pads Tires and wheels Limit switches alarms and horn Nuts bolts and other fasteners Platform entry mid rail gate Beacon and alarms if equipped Check entire machine for Cracks in welds or structural components Dents or damage to machine Battery packs and connections Compartment covers and latches TABLE A PROCEDURES A 4 Check the Hydraulic Oil Level Maintaining the hydraulic oil at the proper level is essential to machine operation I
123. in the DOWN direction and check voltage on the wht red 6 wire at the boom function proportional valve coil item AU or BU or Z 34 22 after serial number 1733 and Z 34 22N after serial number 2226 Hold the function enable toggle switch to either side and move the secondary boom toggle switch TS60 in the DOWN direction and check voltage on the wht red 6 wire at the boom function proportional valve coil item AU or BU or CH 24N Continued on page 48 2 34 22 before serial number 153 and Z34 22N before serial number 304 Move the secondary boom toggle Switch in the DOWN direction and check voltage at TB6 2 34 22 after serial number 152 and Z34 22N after serial number 303 Hold the function enable toggle Switch to either side and move the secondary boom toggle switch in the DOWN direction and check voltage at TB6 Turn key switch to platform controls and pull both Emergency Stop buttons out to the ON position With the boom function speed controller turned to 9 press down the foot switch and move the secondary boom toggle switch Z 34 22 before serial number 1734 and Z 34 22N before serial number 2227 TS2 Z 34 22 after serial number 1733 and Z 34 22N after serial number 2226 TS10 in the DOWN direction Check voltage at blk red at the boom function speed controller ov Continued on the next page Repair open in wht red wire circuit from TB6 to boom function 24V proporti
124. individual and move any boom boom toggle switch to function toggle switch the boom function speed and check the voltage at controller the red wire on the boom function speed controller 20V or more Press down foot switch Adjust boom function and move any boom speed controller OR function toggle switch replace boom function and check the voltage at speed controller OR the blk red wire on the consult Genie Industries boom function speed Service Department controller 20V or more Press down foot switch Repair open in wire and move any boom circuit with diode from function toggle switch the boom function speed and check voltage at controller to TB6 OR TB6 replace diode 20V or more Continued on the next page Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 5 29 Section 5 Troubleshooting Flow Charts First Edition Third Printing EE EE NSN CHART 7 With the boom function Repair open in wht red speed controller turned wire circuit from to 9 press down foot proportional valve coil to switch and move any TB6 boom function toggle switch and check voltage at the wht red wire on the proportional valve coil item AU or BU or CH Continued from the previous page 20V or more 0 or infinite ohms Disconnect the wire to the proportional valve coil Test the resistance of the valve coil See Repair Section Replace valve coil 19 to 20 ohms Z 34 22 before serial number 15
125. motor Replace the drive motor that has a resistance of more than 1 ohm yes Repair open in motor armature cables from terminals M and B on the motor controller to each drive motor Remove the motor bos Repair open in the controller harness kilohms ground wire circuit from connector from the pin 17 on the motor motor controller Check controller harness continuity from the grn connector to PR1 wire that was just removed from PR1 to the B terminal on the motor controller more than 500 kilohms less than Check continuity from 500 pin 17 grn wire on the motor controller to 40015 me motor B terminal on the motor i controller more than 500 kilohms Please begin troubleshooting from beginning of chart Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 5 113 Section 5 Troubleshooting Flow Charts Chart 29C Motor Controller Fault Code 34 Missing Main Contactor OR Main Contactor Did Not Close Z 34 22 after serial number 1733 and Z 34 22N after serial number 2226 Troubleshooting drive function faults may also be accomplished by using the hand held pendant motor controller programmer Genie part number 56303 Be sure to check the motor controller status indicator light on the ground control box or on the motor controller If the motor controller status indicator light is flashing a fault code refer to the fault code chart at the be
126. motor controller preventing proper cooling of the controller OR check for mechanical restrictions causing excessive load on the machine Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 5 Troubleshooting Flow Charts All Functions Will Not Operate Be sure key switch is in the appropriate position Be sure the Emergency Stop buttons are pulled out to the oN position Be sure the circuit breaker and fuses are not tripped or blown Be sure the battery packs are properly connected and fully charged If the Error Indicator light is on at the platform controls please refer to the specific chart that relates to the error code that is displayed on the ECM Disconnect battery packs and check voltage on each pack Connect battery packs and check voltage on the input side of 100A fuse F3 Check voltage on the output side of 100A fuse F3 Check voltage at the input side of 10A circuit breaker CB1 Check voltage at the output side of circuit breaker CB1 Check voltage at the input side of Emergency Stop button P1 Continued on the next page less than Check battery condition 24V or more Replace 100A fuse F3 and replace bad batteries OR check for short circuits OR check battery cables OR consult Genie Industries Service Department Repair open in 24V supply cables positive and negative from the battery
127. on toggle switch OR repair open in the red 1 wire circuit from toggle switch to TB1 OR replace toggle switch Repair open in the red 1 wire circuit from TB1 to the primary boom up directional valve coil OR repair open in the brn ground wire circuit to the manifold Repair open in the red 3 wire circuit from primary boom toggle switch to 1 Genie 7 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 5 Troubleshooting Flow Charts CHART 9 0 or infinite ohms Disconnect the red 1 Continued from the wire to the primary Replace the primary previous page boom up directional valve coil item AD or BD or CU and test the resistance of the valve coil See the Repair Section Exchange the primary and secondary boom directional valves items AD and AE or items BD and BE or items CU and CT Activate the primary boom UP function Replace the defective directional valve function operates boom up directional valve coil Check for mechanical restrictions keeping the primary boom up function from operating OR repair the cylinder or cylinder counterbalance number 153 and valve OR consult Genie Z34 22N before serial Industries Service number 304 Move the Department primary boom toggle switch in the up direction and check the pressure Z 34 22 after serial number 152 and Z34 22N after serial number 303
128. operate each machine function through a full cycle Result All machine functions should operate smoothly Push in the Emergency Stop button to the position Result No function should operate The machine should stop As a Safety feature selecting and operating the ground controls will override the platform controls including the Emergency Stop button 4 6 Genie 7 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 4 Scheduled Maintenance Procedures A 7 Test the Auxiliary Power Operation Detection of auxiliary power system malfunctions is essential for safe machine operation An unsafe working condition exists if the auxiliary powered functions do not operate in the event of a main power loss Auxiliary power is designed for short term emergency use only Excessive use will result in battery drain and component damage 1 Turn the key switch to ground control and pull out the Emergency Stop button to the position 2 Liftthe red auxiliary power switch cover 3 Simultaneously hold the auxiliary power switch in the direction while activating each function through a partial cycle O Result Each function should operate smoothly 4 Turn the key switch to platform control 5 Atthe platform controls pull out the Emergency Stop button to the ow position then press down the foot switch Result Each function TABLE A PROCEDURES Lift the
129. or serious injury Orange used to indicate the AWARNING presence of a potentially hazardous situation which if not avoided could result in death or serious injury Yellow with safety alert symbol ACAUTION used to indicate the presence of a potentially hazardous situation which if not avoided may cause minor or moderate injury Yellow without safety alert symbol used to indicate the presence of a potentially hazardous situation which if not avoided may result in property damage CAUTION Green used to indicate operation or maintenance information Indicates that a specific result is expected after performing a series of steps Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 7 1 Section 7 Repair Procedures First Edition Third Printing Platform Controls 1 1 Controllers The drive controller joystick is connected by a control cable to the drive motor controller located under the non steer end drive chassis cover Maintaining the controllers at the proper setting is essential to safe machine operation Each controller should operate smoothly and provide proportional speed control through its entire range of motion For further information or assistance contact the Genie Industries Service Department boom function speed controller drive printed circuit board drive controller brake printed circuit board Drive Controller Adjustments Z 34 22 before seria
130. overflow 4 Pump grease into the gear until you see it coming out of the side of the gear housing Lubricant Type Multipurpose grease TABLE C PROCEDURES 5 Replace the Drive Hub Oil 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 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 both plugs and drain the oil 3 Drive the machine until one plug is at the top and the other is at 90 degrees 4 Fill the hub with oil from the top hole until the oil level is even with the bottom of the side hole Part No 36540 Genie Z 34 22 amp Genie Z 34 22N Section 4 Scheduled Maintenance Procedures First Edition Third Printing TABLE C PROCEDURES 5 Apply pipe thread sealant to the plugs then install the plugs 6 Repeat this procedure for each drive hub Drive Hub Oil Capacity before serial number 1734 49 1 and 35 1 models 17 fluid ounces 0 5 liters after serial number 1733 47 1 models 25 6 fluid ounces 0 76 liters Type SAE 90 multipurpose hypoid gear oil API service classification GL5 C 6 Bleed the Platform Rotator See Repair procedure 2 3 How to Bleed the Platform Rotator Genie Z 34 22 amp Genie Z 34 22N Part No 36540 F
131. pivot pin Use a soft metal drift to remove the barrel end pivot pin 7 Use a soft metal drift to remove the jib boom lift cylinder rod end pivot pin Remove the jib boom lift cylinder from the machine AWARNING Crushing hazard The jib boom lift cylinder may fall when the pins are removed if it is not properly supported by the overhead crane Genie 7 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 7 Repair Procedures Primary Boom Components 4 1 4 2 Plastic Cable Track Primary Boom The primary boom cable track guides the cables How to Shim the Primary Boom and hoses running up the boom It can be repaired link by link without removing the cables and hoses Measure each wear pad Replace that run through it Removing the entire primary the pad if it is less than 0 41 inch boom cable track is only necessary when 1 cm thick If the pad is more performing major repairs that involve removing the than 0 41 inch 1 cm thick primary boom perform the following procedure How to Repair the Plastic Cable 1 Extend the boom until the wear pads are accessible Track 2 Loosen the wear pad mounting fasteners CAUTION Component damage hazard The primary boom cable track can be damaged if it is twisted 3 Install the new shims under the wear pad to obtain zero clearance and zero drag 4 Tighten the mounting fasteners 5 Extend and retract the boom through an entire cycle Check
132. press down the foot switch and move the platform rotate toggle switch in the RIGHT direction Check voltage at the platform rotate right directional valve coil oV Repair open in power supply wiring to platform rotate toggle switch on ground controls OR on the platform controls Repair open in wire circuit from TB18 to platform rotate right directional valve coil OR repair open in brn ground wire circuit to the manifold Repair open in the ground wire circuit on the platform rotate right directional coil Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 5 Troubleshooting Flow Charts 21 Disconnect the wires 0 or from the platform rotate infinite right directional valve ohms coil Test the resistance of the valve coil See Repair Section Continued from the previous page Exchange the platform rotate right and jib boom up directional valves item B and A Activate the platform rotate RIGHT function function inoperative yer a0 e Ted psi 0 to 207 bar pressure gauge at the quick disconnect coupling on p the boom function manifold and activate the platform rotate right function Check for mechanial restrictions keeping platform rotate right function from moving OR the Z 34 22 before serial number 1734 and Z 34 22N before serial number 2227 0 030 orifice item C Z 34 22 a
133. pressure gauge to the test port on the function manifold 2 Turn the key switch to ground control and pull out the Emergency Stop button to the position 3 Z 34 22 before serial number 153 and Z 34 22N before serial number 304 Move 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 Z 34 22 after serial number 152 and Z 34 22N after serial number 303 Hold the function enable toggle switch to either side and move 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 Primary boom extend relief valve specifications Before serial number Z34 22 2901 Z34 22N 3533 Pressure 1800 psi 124 bar After serial number Z34 22 2900 Z34 22N 3532 Pressure 2800 psi 193 bar MANIFOLDS 4 Turnthe machine off Hold the relief valve and remove the cap Z 34 22 Before serial number 674 item AT From serial number 674 to 1733 item BT From serial number 1733 to 3215 item CG Removed after serial number 3215 Z 34 22N Before serial number 935 item AT From serial number 935 to 2226 item BT From serial number 2226 to 3766 item CG Removed after serial number 3766 5 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure In
134. serial number 304 to 2226 Do not adjust the controllers unless the static battery supply voltage is above 24V DC This procedure will require the use of two multi meters One will be used for measuring amperage and the other for voltage AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches andother jewelry 1 Block the steering wheels and center a lifting jack under the drive chassis between the non steer tires boom function speed controller drive and brake printed circuit board drivecontroller om Part No 36540 Genie Z 34 22 amp Genie Z 34 22N Section 7 Repair Procedures First Edition Third Printing PLATFORM CONTROLS 2 Raise the drive chassis approximately 1 to 2 inches 2 5 to 5 cm off the ground and place jack stands under the chassis for support 3 Open the platform control box lid and locate the printed circuit board on the drive controller 8 XOG terminal activates max out range terminal D drive output terminal X terminal ground terminal positive terminal B brake output drive lo range trimpot drive threshold trimpot drive max out trimpot brake threshold trimpot brake max out trimpot a Fa lt 4 Disconnect the white red wire from the B
135. side and move the primary boom toggle Switch TS12 in the down direction and check voltage on the wht red 6 wire at the boom function proportional valve coil item AU or BU or CH Z 34 22 after serial number 1733 and Z 34 22N after serial number 2226 Hold the function enable toggle switch to either side and move the primary boom toggle switch TS61 in the DOWN direction and check voltage on the wht red 6 wire at the boom function proportional valve coil item CH 24N Continued on page 40 Hold the function enable toggle switch to either side and move the 24V primary boom toggle switch in the DOWN direction and check the voltage at TB6 Turn key switch to 24V platform controls and pull both Emergency Stop buttons out to the position With the boom function speed controller turned to 9 press down the foot switch and move the primary boom toggle switch Z 34 22 before serial number 1734 and Z 34 22N before serial number 2227 TS3 Z 34 22 after serial number 1733 and Z 34 22N after serial number 2226 TS11 in the DOWN direction Check voltage at TB6 oV Press down the foot switch and move the primary boom toggle switch in the DOWN direction Check voltage at the red wire on the boom function speed controller 24V Continued on the next page Repair open in wht red 6 wire circuit from TB6 to boom function proportional valve coil OR repair open in brn ground wire c
136. that there are no leaks Clean up any oil that may have spilled during the replacement procedure Properly discard the oil Cil filters Genie part numbers 734 22 before serial number 431 45087 from serial number 431 to 809 44788 from serial number 810 to 2265 58995 from serial number 2266 to 3110 74346 after serial number 3110 74634 234 223 before serial number 1117 44788 from serial number 1117 to 3032 58995 from serial number 3033 to 3659 74346 after serial number 3660 74634 Part No 36540 Genie 7 34 22 amp Genie Z 34 22N 4 27 Section 4 Scheduled Maintenance Procedures First Edition e Third Printing Table C Procedures C 1 C 2 Check the Primary Boom Check the Turntable Rotation Wear Pads Bearing Bolts Maintaining the primary boom wear pads in good Maintaining proper torque on the turntable bearing condition is essential to safe machine operation bolts is essential to safe machine operation Wear pads are placed on boom tube surfaces to Improper bolt torque could result in an unsafe provide a low friction replaceable wear pad operating condition and component damage between moving parts Improperly shimmed wear pads or continued use of worn out wear pads may 1 Raise the secondary boom and place a safety result in component damage and unsafe operating chock on the secondary boom lift cylinder conditions Carefully lower the boom onto the lift cylinder safety chock 1 Turn the key switch to groun
137. the entire proportionally controlled speed range 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 Emergency Stop button to the position at both the ground and platform controls 3 Raise the primary boom more than 5 feet 1 5 m 4 Move the lift drive switch to the Drive position if equipped 5 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 6 Bring the machine to maximum drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line 7 Continue at full speed and note the time when the machine reference point passes over the finish line Drive speeds maximum raised or extended position Drive speed raised or extended 0 6 mph 1 km h 40 40 12 2 m 40 sec Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 4 Scheduled Maintenance Procedures B 16 Test the Alarm Package if equipped The alarm package includes Travel alarm Descent alarm Flashing beacon Alarms and a beacon are installed to alert operators and ground personnel of machine proximity and motion The alarm package is installed on the ground controls side turntable
138. the Genie Industries Service Department Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 5 21 Section 5 Troubleshooting Flow Charts First Edition Third Printing EE CHART 5 Adjust the relief valve on Z 34 22 before serial Continued from the the function manifold number 153 and Z 34 previous page item AB or BB or BC 22N before serial all the way in number 304 Move clockwise counting the more TS13 in the RETRACT number of turns Move direction and adjust the the boom extend retract relief valve pressure to switch in the RETRACT 3200 PSI OR consult direction Check the Genie Industries Service pressure Department Z 34 22 after serial number 152 and Z 34 22N after 303 Hold the function enable toggle switch to either side and move TS13 in the RETRACT direction and adjust the relief valve pressure to 3200 PSI OR consult Genie less than 3200 PSI Industries Service Department Z 34 22 before serial Check function pump Replace the pump number 153 and Z 34 See Repair section 22N before serial number 304 Move any boom function toggle switch and manually activate the boom Replace the boom proportional valve OR proportional valve item replace the differential AU or BU or CH Does sensing valve item the function operate or BA or CQ OR
139. the cylinder down through the secondary boom enough to access the hydraulic hoses Do not pinch the hoses Component damage hazard Hoses CAUTION can be damaged if they are kinked or pinched Tag disconnect and plug the hydraulic hoses from the secondary boom lift cylinder Cap the fittings on the secondary boom lift 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 9 Remove the cylinder through the top of the secondary boom Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 7 33 Section 7 Repair Procedures First Edition Third Printing Ground Controls 6 1 Control Relays Relays used for dual function switching are double pole double throw DPDT relays How to Test a Double Pole Double Throw Relay AWARNING Electrocution bu m hazard Contact with electrically charged circuits could cause death or serious injury Remove all rings watches and other jewelry This procedure covers fundamental relay testing and does not specifically apply to all varieties of relays 1 Turn the key switch to the orr position and remove the key 2 Label and then disconnect all the wiring from the relay to be tested 3 Connect the leads from an ohmmeter to each terminal combination and check for continuity Terminals 7 and 8 represent the coil
140. the motor controller Test the motor controller See Repair Section Check for loose or open connections at the drive motors and motor controller OR replace the defective drive motor OR test the motor controller See Repair Section Replace the motor controller Replace the motor controller Part No 36540 Genie Z 34 22 amp Genie Z 34 22N Section 5 Troubleshooting Flow Charts First Edition Third Printing FAULT CODE CHART Z 34 22 AFTER SERIAL NUMBER 1733 AND Z 34 22N AFTER SERIAL NUMBER 2226 Fault Code Programmer Condition Possible Causes Diagnostic Display THROTTLE FAULT 1 THROTTLE FAULT 2 MAIN CONT WELDED Machine will not drive Controller fault indicator light on at the platform controls Machine will not drive Controller fault indicator light on at the platform controls Machine will not drive Controller fault indicator light on at the platform controls Machine will not drive Controller fault indicator light on at the platform controls Open in wht red wire 32 at pin 14 or 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 Pin 14 wht red 32 is shorted to power or ground OR the potentiometer on the drive joystick is defective Main contactor PR1 coil defective OR brak
141. to 4260 qaunria HM eoa S4oria L qau 9uoO c LHM LHNV Q3H NOLLdO C 3SN3 QVOT1 Section 6 Schematics B SPARE WIRES BLK 1 BLK WHT 1 BLK RED 1 BLU WHT 1 BLU RED 1 GRN WHT 1 ORG 1 ORG BLK 1 DESCRIPTION EMERGENCY STOP BUTTON HORN BUTTON DRIVE CONTROLLER BOOM FUNCTION SPEED CONTROLLER AUXILIARY POWER TOGGLE SWITCH PLATFORM ROTATE TOGGLE SWITCH JIB UP DOWN TOGGLE SWITCH PLATFORM LEVEL TOGLE SWITCH SECONDARY BOOM UP DOWN TOGGLE SWITCH PRIMARY BOOM UP DOWN TOGGLE SWITCH TURNTABLE ROTATE TOGGLE SWITCH EXTEND RETRACT TOGGLE SWITCH DRIVE ENABLE TOGGLE SWITCH TILT ALARM DRIVE ENABLE LIGHT BATTERY CHARGE INDICATOR OPTION REMOVE JUMPER JP1 FOR CE VERSION REMOVE THIS WIRE WHEN LOAD SENSE OPTION IS REQUIRED TS15 9 TS9 TS12 i w P3 ooo ee gt XT gt O LO 9007 8 a _ TS11 2 2Q amp 2
142. to safe operation and good machine performance If the turntable rotates past the rotation stop component damage may result 1 Turn the key switch to platform control and pull out the Emergency Stop button to the on position at both ground and platform controls Move the lift drive switch to the position if equipped 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 Rotate the turntable to the right full circle as far as it will go Result Movement should stop when the primary boom reaches midpoint between the steer tires 4 24 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 4 Scheduled Maintenance Procedures TABLE PROCEDURES B 18 B 19 Check the Electrical Contactors Perform Hydraulic Oil Analysis Maintaining the electrical contactors in good See D 1 Test or Replace the Hydraulic Oil condition is essential to safe machine operation Failure to locate a worn or damaged contactor could result in an unsafe working condition and component damage 1 Remove the non steer drive chassis cover and locate the electrical contactors mounted on the component mounting panel 2 Visually inspect the contact points of each contactor for the following items Excessive burns e Excessive arcs Excessive pitting Electrocution burn hazard Contact AWARNI
143. trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage 7 6 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 7 Repair Procedures 11 Set the drive max out on the circuit board Press down the foot switch and slowly move the control handle all the way to the FoRwARD position Adjust the max out trimpot on the circuit board to 5 to 5 2V DC Turn the max out trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage 12 Raise the primary boom approximately 2 feet 0 6 m to activate the drive limit switch 13 Set the drive lo range on the circuit board Press down the foot switch and move the control handle all the way to the FonwARD position Adjust the drive lo range trimpot on the circuit board to 2 4 to 2 7V DC Turn the lo range trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage 14 Lower the boom to the stowed position and remove the jack stands from under the drive chassis 15 Raise the primary boom approximately 2 feet 0 6 m to activate the drive limit switch 16 Create start and finish lines by marking two lines on the ground 40 feet 12 2 m apart Choose a reference point on the machine as a visual reference for use when crossing the start and finish lines 17 Bring the machine to top drive speed before reaching the start lin
144. up down 20 25 ft lbs 27 34 Nm 2 Solenoid valve 3 position 4 way Bases Platform rotate right left 20 25 ft lbs 27 34 Nm Flow regulator valve 0 3 1 14 L MIN eus Platform rotate circuit 20 25 ft lbs 27 34 Nm m 5 2 Valve Coil Resistance Specification Description Measurement 3 position 4 way valve 20V DC 22 Q schematic items A and B Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 7 53 Section 7 Repair Procedures First Edition Third Printing M X X G ari MANIFOLDS 8 8 Steer Brake Manifold Components 7 34 22 before serial number 781 and Z 34 22N before serial number 1030 Index Schematic No Description Item Function Torque 1 Check valve sesesseene Gsm Brake CUCUIE cents 25 30 ft lbs 34 41Nm 2 Normally open poppet valve Es Brake circult eee 25 30 ft lbs 34 41Nm 3 position 4 way spool valve Steer left right 10 12 ft lbs 14 16Nm 4 Orifice washer 0 040 inch 1 02 mm J Brake circuit 5 Pressure Brake circuit 6 Normally closed poppet valve Lu Brake Circuit sosanna 25 30 ft lbs 34 41 7 Orifice washer 0 052 inch 1 32 mm M
145. valve pressure 221 bar Primary boom down relief Z 34 22 before serial number 3216 1400 psi 97 bar after serial number 3215 1600 psi 110 bar Z 34 22N before serial number 3767 1400 psi 97 bar after serial number 3766 1600 psi 110 bar Secondary boom down relief 1600 psi valve pressure 110 bar Primary boom extend relief 1800 psi valve pressure 124 bar Z 34 22 before serial number 2901 1800 psi 124 bar from serial number 2901 to 3215 2800 psi 193 bar Z 34 22N before serial number 3533 1800 psi 124 bar from serial number 3533 to 3766 2800 psi 193 bar Turntable rotate relief valve pressures Z 34 22 before serial number 674 1750 psi 121 bar from serial number 674 to 1733 Not adjustable after serial number 1733 1100 psi 76 bar Z 34 22N before serial number 935 1750 psi 121 bar from serial number 935 to 2226 Not adjustable after serial number 2226 1100 psi 76 bar SPECIFICATIONS Auxiliary pump Type Fixed displacement gear pump Displacement 0 75 gpm 2 8 l min Part No 36540 Genie Z 34 22 amp Genie Z 34 22N Section 2 Specifications First Edition Third Printing E SPECIFICATIONS Hydraulic Hose and Fitting Torque Specifications Your machine is equipped with Parker Seal Lok O ring face seal fittings and hose ends Machines that utilize Parker Seal Lok O ring face seal hoses and fittings require that the fittings and hose ends be torqued to specification when they are remo
146. 1 function or steer brake 2 34 22N after 303 manifolds could have an internal defect Consult le Genie Industries Service side and move any Department boom function toggle switch and manually activate the boom proportional valve item AU or BU or CH Does the function operate Continued on the next page 5 22 Genie 7 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 5 Troubleshooting Flow Charts CHART 5 no Continued from the Z 34 22 before serial continuity Repair open in the previous page Due d am ground wire circuit number 304 Check for continuity in the ground wire circuit from the proportional valve coil to TB48 to the wht wire at the boom function speed controller Z 34 22 after serial number 152 and Z 34 22N after 303 Check for continuity in the ground wire circuit from the proportional valve coil to ground continuity 2 34 22 after serial number 152 and 2 34 22 after 303 Move any boom function toggle switch and check voltage on the wht red 6 wire on the proportional valve coil 2 34 22 after serial number 152 and 2 34 22 after 303 Hold the function enable Replace defective coil toggle switch to either side and move any boom function toggle switch and check voltage on the wht red 6 wire on the proportional valve coil Continued on the next page Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 5 293 Section
147. 123 Section 5 Troubleshooting Flow Charts First Edition Third Printing CHART 34 Check voltage at the Repair open in wht 8 odds Tn the wht 8 wire on the input wire from TB50 to the page side of LS4 input side of LS4 Check to make sure LS4 is not being activated when the secondary boom is in the lowered position OR repair open in blk 8 wire circuit from the output side of LS4 to TB40 OR replace LS4 contacts OR replace LS4 Check voltage at TB40 Check voltage at pin 3 Repair open in org 40 on the motor controller wire circuit from TB40 to harness connector pin 3 on the motor controller harness connector Test the motor controller see Repair Section OR consult Genie Industries Service Department 5 124 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 5 Troubleshooting Flow Charts Machine Drives At Full Speed With Platform Raised Or Extended Z 34 22 before serial number 1734 and Z 34 22N before serial number 2227 Remove the machine from service immediately Be sure the wiring to the limit switches is intact and shows no signs of damage or corrosion Be sure the primary boom drive limit switch is being activated by the cam Turn key switch to platform controls and pull both Emergency Stop buttons out to the ON position With the primary boom raised above the limit switch LS2 check voltage on 49 E
148. 20 to PR2 Part No 36540 Genie Z 34 22 amp Genie Z 34 22N Section 5 Troubleshooting Flow Charts First Edition Third Printing CHART 2 2 34 22 before serial number 153 and Z 34 22N before serial number 304 Move the primary boom extend retract toggle switch in the RETRACT direction and check voltage at terminal 6 on CR2 2 34 22 from serial number 153 to 1733 and Z 34 22N from serial number 304 to 2226 Hold the function enable switch to either side and move the primary boom extend retract toggle switch in the RETRACT direction and check voltage at terminal 9 on CR8 2 34 22 after serial number 1733 and 2 34 22 after serial number 2226 Hold the function enable switch to either side and move the primary boom extend retract toggle switch in the RETRACT direction and check voltage at terminal 30 on CR20 Continued from the previous page Continued on the next page Z 34 22 before serial number 153 and Z 34 22N before serial number 304 Repair open in grn wht wire circuit from TB19 to terminal 6 on CR2 OR repair open in function switch wire circuit with diode to TB19 OR repair open in wire circuit from the key switch ground controls contact to the function switch wire circuit OR replace primary boom extend retract toggle switch OR contact Genie Industries Service Department Z 34 22 from serial number 153 to 1733 and Z 34 22N from serial number 304 to 2226 Re
149. 3 and Z34 22N before serial number 304 Repair open in the blu wht wire circuit from the proportional valve coil to 48 to the boom function speed controller OR replace proportional valve item AU or BU or CH OR troubleshoot lift and drive functions individually OR consult Genie Industries Service Department Z 34 22 after serial number 152 and Z34 22N after serial number 303 Repair open in brn ground wire circuit from proportional valve to ground OR replace proportional valve item AU or BU or CH OR troubleshoot lift and drive functions individually OR consult Genie Industries Service Department 5 30 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Platform Controls Inoperative Ground Controls Operate Normally Z 34 22 after serial number 1733 and Z 34 22N after serial number 2226 Be sure key switch is in the appropriate position Be sure the Emergency Stop buttons are pulled out to the oN position Be sure the battery packs are properly connected and fully charged Turn key switch to platform controls and pull both Emergency Stop buttons out to the ON position Check voltage at the red wire on the input side of the platform controls contact of the key switch this wire should originate at Emergency Stop button P1 24N Check voltage on the output side of the platform controls contact on the key switch 24N Check voltage
150. 3 in the RETRACT direction and check voltage on the wht red 6 wire at the boom function proportional valve coil item AU Z 34 22 from serial number 153 to 1733 and Z 34 22N from serial number 304 to 2226 Hold the function enable toggle switch to either side and move the primary boom extend retract toggle switch TS13 in the RETRACT direction and check voltage on the wht red 6 wire at the boom function proportional valve coil item AU or BU Z 34 22 after serial number 1733 and Z 34 22N after serial number 2226 Hold the function enable toggle switch to either side and move the primary boom extend retract toggle switch TS63 in the RETRACT direction and check voltage on the wht red 6 wire at the boom function proportional valve coil item CH 24V Continued on page 57 2 34 22 before serial number 153 and 234 22 before serial number 304 Movethe 24V primary boom extend retract toggle switch in the RETRACT direction and check voltage at TB6 2 34 22 after serial number 152 and Z34 22N after serial number 303 Hold the function enable toggle Switch to either side and move the primary boom extend retract toggle Switch in the RETRACT direction and check voltage at TB6 Turn key switch to 24V platform controls and pull both Emergency Stop buttons out to the position With the boom function speed controller turned to 9 press down the foot switch and move the primary boom extend ret
151. 34 22 amp Genie Z 34 22N CX sd ET E 4 D A GS N 0 9 0220 6 EE OOOO D Part No 36540 Section 7 Repair Procedures I M MANIFOLDS 8 4 Valve Adjustments Function Manifold How to Adjust the System Relief Valve 1 2 3 Perform this procedure with the boom in the stowed position Connect a 0 to 5000 psi 0 to 345 bar pressure gauge to the test port on the function manifold Turn the key switch to ground control and pull out the Emergency Stop button to the position Z 34 22 before serial number 153 and Z 34 22N before serial number 304 Move 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 Z 34 22 after serial number 152 and Z 34 22N after serial number 303 Hold the function enable toggle switch to either side and move 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 System relief valve specifications Pressure 3200 psi 221 bar First Edition Third Printing 4 Turn the machine off Hold the relief valve and remove the cap Z 34 22
152. 58 560 7562 GRN BLK 44A L R GRN 43A Ou tou BLU BLI 11A BLU 10A RED CH SWITCH PANEL LABEL DESCRIPTION P1 EMERGENCY STOP BUTTON KS1 KEY SWITCH TS51 AUXILIARY TOGGLE SWITCH TS55 FUNCTION ENABLE TOGGLE SWITCH TS57 PLATFORM ROTATE TOGGLE SWITCH TS58 JIB UP DOWN TOGGLE SWITCH TS59 PLATFORM LEVEL TOGGLE SWITCH TS60 SECONDARY BOOM UP DOWN TOGGLE SWITCH TS61 PRIMARY BOOM UP DOWN TOGGLE SWITCH TS62 TURNTABLE ROTATE TOGGLE SWITCH TS63 BOOM EXTEND RETRACT TOGGLE SWITCH CB1 CIRCUIT BREAKER CONTROLS 10A CB2 CIRCUIT BREAKER CONTROLS RETURN 10A J1 BRAKE RELEASE JACK HM HOURMETER CH CHASSIS HARNESS MH MANIFOLD HARNESS SP SWITCH PANEL CR CONTROL RELAY A2 TRAVEL ALARM DESCENT ALARM OPTION L3 CONTROLLER STATUS LED TILT SENSOR uis WHT 28D BLK BRN CB2 CB2 L3 BRN 52D te ap BLK CH BRN CH ORG RED 42A BRN BRN ORG N P1 ONC O CB1 0 KS1 Qo Ji NO NO E 7 TS63 ORG TS58 TS61 ORG e ORG TS60 2 TS55 TS59 O 4j a N TS62 DESCENT ALARM WIRING OPTION O CONTROL RELAY I D SPARE WIRE LIST CR1 SECONDARY 48V POWER 2 PRIM
153. 6 WH RD C3B 6 E WH RD os M g T o 8 zE E z 5838 amp coro 1 NN 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 9 i 1 C2P 5 C43JU GR dye 2 1 C2P 6 C44JD GR BK C2B 6 1 1 8 cara C44JD WH 47 4 C43JU BK i 8 7 RIGHT P z i 2 z 5 C47 1 C18PRLOR z op m ER 1 s 55 EFT 5 m 47 2 C17PRR BL ee 8 39 Ci8PRRGR BK C4B 6 2062 7 818 5 C17PRLGR C4B 5 5 818 z B 8 21 mi UP gt ote ia 5 iat Le ORIBK i 55 DOWN aa B c Ed 14 gt aa C4P 2 C14PLU OR C4B 2 C4P 3 C15PLD ORBK C4B 3 EXTEND gt ter 25 i 8 g 7 C3B 7 C3P 8 C8PBR BKWH C3B 8 uP F gt 7 55 gt 29 DOWN g gt E 8 SEE 20 C3P 1 C1PBU RD C3B 1 CaP 2 C2PBD C3B 2 E UP uz 5 m E DOWN Ts lt 5 55 1 1 uo 10 C1OSBUBL C3B 10 11 CHSBDBLBK _ 11 8 y piat WH BK n 4 m AR ni ul a a Fa ze p Q RIGHT C3P 5 C5TRR C3B 5 4 4 CATRL WH C3B 4 g E 9u X x EZ x oa
154. 99 OFF LIMT SPD INP 4 m 4 C498 1 INTERLOCK p 3 il 9 1 3 C29J5H RD WH C1B 3 C493 RDH 1 POTHI yg 2 nex t 85 amp 1 6 C32JSL WH RD C1B 6 C496 WH RD 2 3 a 1 E CIP 5 C31REV WHIBK 1 5 C495 WHIBK i REVERSE 1 1 CIP4 s C30FWD WH 49184 C494 WH FORWARD z DIODE RETURN 9 1 RA2BATOR RD ni 2 48V INPUT 4 ES u 8 EI E g amp I 3 2 zg Bk 4 2 kg lt TN eCG8 o 24 5 gt lt PRIMARY e ene ox lt LIFT PUMP 25 MEM INE PNE e si olor bx oim A 4 AUXILIARY 2 LIFT PUMP HI C48 1 P182BAT RD amp ar a NI ANI UND s PEN JEN JEN E gt NSN x 12 8 STIS Be Nels ereere db sean ft 2 ox ze N e N co Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 1 ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED gt SWITCH SHOWN WITH BOOM EXTENDED 4 ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED B gt SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON STEER WHEEL 6 25 Section 6 Schematics Electrical Schematic 2 3 4 5 6 7 8 Z 34 22 after serial number 4799 Z 34 22N after serial number 5619
155. AKER CONTROLS 10A HM HOUR METER CR1 CONTROL RELAY HORN CR2 CONTROL RELAY AUXILIARY PUMP CR4 PLATFORM LEVEL CUT OUT CE OPTION CH CHASSIS HARNESS MH MANIFOLD HARNESS SP SWITCH PANEL A2 TRAVEL ALARM A3 DESCENT ALARM J1 BRAKE RELEASE JACK First Edition Third Printing Ground Control Panel Wiring Diagram Z 34 22 from serial number 153 to 1733 Z 34 22N from serial number 304 to 2226 Section 6 Schematics E D 1 WHT LS2 52 WHT LS4 LIMIT SWITCH BLK TILT ALARM 51 BRN 2 GROUND CR4 2 BRN CH 50 BRN LS3 BRN SP BLK LS1 BLK LS2 49 LIMIT SWITCH BLU WHT MH BLU WHT 1 48 HOUR METER RED WHT TB46 RED CH 47 RED SP ALARM ORG BLK TB41 4 BRAKE RELEASE N C RED WHT TB47 RED WHT TB29 46 RED WHT SP BRAKE RELEASE REMOTE GRN BLK 1 44 GRN BLK SP JIB DOWN GRN 1 43 GRN SP JIB UP 3 ORG RED CH ORG RED 1 42 48V SUPPLY ORG BLK CH ORG BLK 1 41 ORG BLK TB47 DRIVE COIL PR1 ORG 1 40 BLK LS4 LIMIT SWITCH BLU BLK CH BLU BLK 1 37 BLU BLK TB19 gt H STEER LEFT BLU CH BLU 1 36 BLU TB19 gt STEER RIGHT WHT RED CH WHT RED 1 32 BRAKE FLOW CONTROL WHT BLK CH WHT BLK 1 31 REVERSE PR2 4 WHT CH WHT 1 30 FORWARD PR2 RED WHT CH RED WHT 1 29 RED WHT TB46 BRAKE HS WHT TILT ALARM RED BLK 1 28 TILT ALARM RED CR3 RED 1 27 RED SP AU
156. ARY 48V POWER CR3 AUXILIARY PUMP CR4 HORN 5 BRAKE RELEASE CR10A PLATFORM LEVEL CUTOUT CE OPTION CR10B PLATFORM LEVEL CUTOUT CE OPTION OPTION NUMBERS 1 PLATFORM LEVEL CUTOUT 2 FLASHING BEACON DESCENT ALARM BLK 1 BLK WHT 1 BLK RED 1 BLU WHT 1 BLU RED 1 GRN WHT 1 ORG 1 ORG BLK 1 BRN CB2 BLK OPTION 2 52 BRN CH BRN CR4 GROUND BRN 5 BRN 2 52 BRN MH BRN SP GROUND WHT 6 WHT 8 50 LS2 LS4 JUNCTION BLK 7 BLK 6 49 LS1 LS2 JUNCTION M wHT eLk sP RED WHT CR5 48 RED WHT MH RED WHT SP BRAKE RELEASE GRN BLK 1 44 GRN BLK SP JIB DOWN GRN 1 43 GRN SP JIB UP ORG RED CR1 ORG RED 1 42 ORG RED CH ORG RED L3 SWITCHED 48V BLK 8 40 ORG CH OFF LIMIT SPEED BLueLk 190 BLU BLK 1 37 BLU BLK MH STEER RIGHT BLu 190 BLU 1 36 BLU MH STEER LEFT WHT RED 1 32 WHT RED CH JOYSTICK POT LOW WHT BLK 1 31 WHT BLK CH REVERSE WHT 1 30 WHT CH FORWARD RED WHT 1 29 RED WHT CH 2 WIRE POT REDIBLK TLT WHT TILT RED BLK 1 28 TILT ALARM Z34 22N after serial number 4008 234 22 a er serial number 3308 RED CR3
157. April 1999 Manually activate the secondary boom drive speed limit switch Result The drive speed limit switch arm should move freely and spring return to center A distinct click should be felt and heard 6 Manually activate the primary boom drive limit switch Result The drive speed limit switch arm should move freely and spring return to center A distinct click should be felt and heard 7 Turn the key switch to platform control and pull out the Emergency Stop button to the position at the platform controls TABLE A PROCEDURES 8 Press down the foot switch and slowly move the drive control handle off center Result The machine should move at normal drive speeds 9 Raise the primary boom approximately 5 feet 1 5 m 10 Slowly move the drive control handle off center Result The machine should move at a reduced drive speed 11 Lower the primary boom to the stowed position 12 Raise the secondary boom approximately 5 feet 1 5 m 13 Slowly move the drive control handle off center Result The machine should move at a reduced drive speed 14 Lower the secondary boom to the stowed position 15 Extend the primary boom 12 inches 30 cm 16 Slowly move the drive control handle off center Result The machine should move at a reduced drive speed Raised Drive speed maximum Platform raised 40 40 12 2 m 40 sec Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 4 9
158. BLK FOOT SWITCH O RED BLK TILT K ALARM j RED BLK RED WHT TS9 TS2 TS7 0 1 O TT TS3 TS5 C GRN 12 O Q L 01 4 56 BLK RED d Tod TS6 TS18 L1 O10 a 58 2 NO NC NC BCI ojo E N 8 BRN 6 4 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 6 Schematics Load Sensor Option Diagram 7 34 22 from serial number 1734 to 2060 Z 34 22N from serial number 2227 to 2870 LOAD CELL LABEL DESCRIPTION P2 EMERGENCY STOP BUTTON P3 HORN BUTTON DP1 DRIVE CONTROLLER BP1 BOOM FUNCTION SPEED CONTROLLER TS1 AUXILIARY TOGGLE SWITCH TS7 PLATFORM ROTATE TOGGLE SWITCH TS8 JIB UP DOWN TOGGLE SWITCH TS9 PLATFORM LEVEL TOGGLE SWITCH TS10 SECONDARY BOOM TOGGLE SWITCH LOAD SENSE OPTION TS11 PRIMARY BOOM TOGGLE SWITCH TS12 TURNTABLE ROTATE TOGGLE SWITCH TS13 PRIMARY BOOM EXTEND TOGGLE SWITCH 7815 DRIVE ENABLE TOGGLE SWITCH L1 DRIVE ENABLE LIGHT 12 OVERLOAD LIGHT OPTION CABLE CABLE CABLE 2 1 RED
159. BLK WHT WHT FS REDAWHT BRN WHT FS TS15 TS12 TS10 OO Quo BP1 BLK RED TS7 TS TS8 RED GRN BRN 9 ooo a L1 L2 L o lt 5 5 NC NC 3 2e A TS1 P3 P2 DP1 Part No 36540 Genie 7 34 22 amp Genie Z 34 22N 6 5 Section 6 Schematics First Edition Third Printing Load Sensor Option Diagram Z 34 22 from serial number 2061 to 3577 Z 34 22N from serial number 2871 to 4260 LABEL DESCRIPTION P2 EMERGENCY STOP BUTTON HORN BUTTON DP1 DRIVE CONTROLLER BP1 BOOM FUNCTION SPEED CONTROLLER TS1 AUXILIARY TOGGLE SWITCH TS7 PLATFORM ROTATE TOGGLE SWITCH TS8 JIB UP DOWN TOGGLE SWITCH TS9 PLATFORM LEVEL TOGGLE SWITCH LOAD SENSE OPTION TS10 SECONDARY BOOM TOGGLE SWITCH 7811 PRIMARY BOOM TOGGLE SWITCH 7512 _ TURNTABLE ROTATE TOGGLE SWITCH TS13__ PRIMARY BOOM EXTEND TOGGLE SWITCH 7515 DRIVE ENABLE TOGGLE SWITCH L1 DRIVE ENABLE LIGHT 12 OVERLOAD LIGHT OPTION Z amp amp CABLE CABLE CABLE 2 1 LOAD CELL
160. BLK CH 1 pe n PEDS ORG RED 16A hH Laaa ORG 14B ORG BLK 15B 4 ORG BLK 3 15 ORG BLK CR10B ORG BLK SP PLATFORM LEVEL DOWN ORG 3 14 ORG CRI0A ORG SP PLATFORM LEVEL UP PLATFORM LEVEL CUTOUT CE VERSION ONLY First Edition Third Printing Section 6 Schematics Ground Control Panel Wiring Diagram 7 34 22 from serial number 2000 to 3577 Z 34 22N from serial number 2751 to 4260 C B A LABEL DESCRIPTION RED WHT BRN 1 EMERGENCY STOP BUTTON 1 7 KS1 KEY SWITCH 7551 AUXILIARY TOGGLE SWITCH 955 FUNCTION ENABLE TOGGLE SWITCH O O TS57 PLATFORM ROTATE TOGGLE SWITCH SWITCH PANEL TS58_ JIB UP DOWN TOGGLE SWITCH TS59 PLATFORM LEVEL TOGGLE SWITCH TS60 SECONDARY BOOM UP DOWN TOGGLE SWITCH WHT BLK 19D 48D 561 PRIMARY BOOM UP DOWN TOGGLE SWITCH BRN 52A TS62 TURNTABLE ROTATE TOGGLE SWITCH mem TS63 BOOM EXTEND RETRACT TOGGLE SWITCH NC CB1 CIRCUIT BREAKER CONTROLS 10A HM CB2 CIRCUIT BREAKER CONTROLS RETURN 10A Ji
161. C drive motors and a solid state motor controller designed for series motors A mechanical forward reverse contactor provides directional control of the drive motors These machines also have a proportional braking system which is active in the drive controller joystick range between neutral position and half way to full deflection in both drive directions The drive controller has a 0 5 V DC voltage output which activates the motor controller as well as a proportional coil output for the brake system 2 34 22 machines after serial number 1733 and 2 34 22 machines after serial number 2226 use separately excited Sepex DC drive motors and a Sepex motor controller No forward reverse contactor is required in this system as the controller does the switching automatically The Sepex drive system utilizes regenerative braking which means that the drive motors are used to slow down and stop the machine The resulting Part No 36540 Genie Z 34 22 amp Genie Z 34 22N First Edition Third Printing THEORY OF OPERATION energy is then returned to the batteries Regenerative braking allows the use of a simple non proportional parking brake which applies after the machine has come to a stop or if the Emergency Stop button is pushed in to the position The Sepex motor controller also incorporates self diagnostics An LED on the motor controller will flash a fault code when a fault is present to aid in troubleshootin
162. CHART 1 Turn key switch to Check to see if the key Replace key switch platform controls and switch internal cam is contact for platform check voltage on output activating the platform controls side of the platform controls contact controls contact of the key switch Replace key switch OR refer to Platform Controls Inoperative Chart 7 OR consult Genie Industries Service Department less than Check voltage on the 48V Repair open in 48V input side of 500A fuse F1 supply cables positive and negative from battery packs 48V or more Replace 500A fuse F1 Check voltage on the output side of 500A fuse F1 Troubleshoot lift and drive systems separately OR consult Genie Industries Service Department Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 5 9 Section 5 Troubleshooting Flow Charts First Edition Third Printing Chart 2 Lift Pump Motor Will Not Operate Be sure key switch is in the appropriate position Be sure the Emergency Stop buttons are pulled out to the oN position Be sure the battery packs are properly connected and fully charged Turn key switch to ground controls and pull both Emergency Stop buttons out to the on position 2 34 22 before serial number 153 and Z 34 22N before serial number 304 Move the primary boom extend retract toggle switch TS13 in the RETRACT direction and check voltage at the positive terminal on the lif
163. E LED DRIVE ENABLE LIMIT SWITCH TRAVEL ALARM OPTION BRAKE RELEASE N C VALVE BRAKE RELEASE VALVE BRAKE RELEASE PRESSURE SWITCH STEER LEFT STEER RIGHT HOUR METER AUXILIARY LIFT PUMP CONTACTOR RELAY CR20 LIFT PUMP CONTACTOR RELAY PR2 LIFT PUMP CONTACTOR PR3 AUXILIARY LIFT PUMP CONTACTOR PROPORTIONAL FLOW CONTROL PLATFORM LEVEL CUTOUT CE OPTION 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 OPTION TURNTABLE ROTATE RIGHT TURNTABLE ROTATE LEFT 6 20 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 6 Schematics Electrical Schematic 7 34 22 from serial number 1835 to 2060 7 34 22 from serial number 2448 to 2870 Section 6 Schematics First Edition Third Printing Electrical Schematic 7 34 22 from serial number 2061 to 3577 7 34 22 from serial number 2871 to 4260 A B C D E
164. E RIGHT EXTEND RETRACT ORIRD 1 OR RD C4B 4 16 OR RD CRS DRIVE ENABLE CIDE CI7PRL CE OPTION OR BK C4B 3 15 OR BK MH OR BK SP PLATFORM LEVEL DOWN C15PLD en m AES PLATFORM ROTATELEFT CE OPTION OH CABE OR MH 5 PLATFORM LEVEL UP BERD i ces DRIVE MIGHT C9HRN T LIE Bum cs i Re Reet BL BK 11 11 BUBK MH BUBK SP SECONDARY BOOM DOWN C11SBD aL 3 BL C3B 10 10 BL MH BL SP SECONDARY BOOM UP C10SBU ss PEAT OVERLOAD INPUT OPTION BURD 1 C2B 1 A6 PLAT OVERLOAD ALARM OPTION C3B 8 8 BK WH MH BKMWH SP BOOM RETRACT C8PBR 6 BK C3B 7 7 BK SP BOOM EXTEND C7PBE WHIRD C3B 6 6 WH RD MH WH RD SP BOOM FUNCTION FC C6MFV CABLE 2 C3B 5 5 WH BK NH WH BK SP TURNTABLE ROTATE RIGHT CSTRR Q WH C3B 4 4 WH MH WH SP TURNTABLE ROTATE LEFT C4TRL RD BK C3B 2 2 RD BK MH RD BK SP PRIMARY BOOM DOWN C2PBD RD C3B 1 1 RD SP PRIMARY BOOM UP C1PBU D B A 000000 C4B 000000 000000 C3B oc oCo TO TERMINAL BASE BDD GR WH 19C OR RD C48 2 5 o E o6 OR RELAY BLOCK GRAWHECASETE 22 CONTROL RELAY LD cal Gna CRS ona SECONDARY 48V POWER CR2 PRIMARY 48V POWER CABLEH BR 52A AUXILIARY PUMP 000000 RD WH C3B 3 L HORN BRAKE RELEASE e BK
165. ED WHT BRAKE RELEASE VALVE BRAKE PRESSURE SWITCH BLU 1 BLU 36 STEER LEFT TB36 TB37 BLU BLK 1 BLU BLK 437 Gk STEER RIGHT STEER v Y y DP1 ORG RED 4 4 WHT BLK 2 HOUR METER CONTROL BOX GROUND CR3 RED 27 AUXILIARY J LIFT PUMP RELAY AUX PUMP 1 2 3 4 5 RED TS51 RED 4 T827 GRN WHT 19 RED 1 LVI BCI OPTION First Edition Third Printing CR20 PRIMARY LIFT PUMP RELAY PR2 PRIMARY LIFT PUMP CONTACTOR ORG RED 48V TB19 GRN WHT 3 m GRN WHT Rm PR3 AUXILIARY LIFT PUMP CONTACTOR PROPORTIONAL FLOW CONTROL DISCHARGE SET TO BRN WHT RED 3 WHT O 1 SET TO RED RED GRN BLK RED BLK ROTARY OEM FLOW CONTROL BRN JIB BP1 GRN WHT 19 JIB BOOM UP JIB BOOM DOWN WHT RED 6 GRN 1 JIB GRN BLK 1 PLATFORM ROTATE RIGHT PLATFORM ROTATE LEFT TB18 BLK JIB WHT JIB PLATFORM ROTATE TB17 PLATFORM LEVEL CUTOUT CE OPTION GRN BLK 3 PLATFORM ROTATE SRIGHT GRN 3 a ORG 3 PLATFOR
166. ETED SLAVE CYLINDER Io af a nn 2 34 22 AFTER SERIAL NUMBER 581 T Z 34 22N AFTER SERIAL NUMBER 767 5 Li PLATFORM ROTATE SECONDARY PRIMARY EXTENSION fe 4 9 T o CYLINDER CYLINDER CYLINDER NEP MED RN cum i RE T 0 032 ZEE bod An AUXILIARY PRIMARY 0 81 mm MEN MEET OSE PUMP mC PUMP Se Tet HM oO WM dn HW 0 5 GPM 1 7 GPM TURNTABLE i Mu 1 9 L min 6 4 L min 8 1 ROTATE ae S Lid pw Noa 2500 PSI 2500 PSI e 172 bar 172 100 3 1 3 1 MICRON MASTER 5 9 CU IN ec eee E o o CYLINDER REV E qe Sa ge 1 Q wf Li Li Q TANK 4 GALLON p 9 M E d M 15 1 Liters Eli NC 3000 PSI 3000 PSI 2500 PSI 207 bar 207 bar 172 bar 1 5 JIB PLATFORM 6 1 51 3 1 3 1 ROTATE ENS TENA 5 C NEN LUE gt RES O COA 2 TR CER MANIFOLD oos BOOM FUNCTION E 2 i m T2 076mm PR2 MANIFOLD LEZ ELE 1 e i do 3200 PSI Y i d Moo Er S xs FO pH Ut Uo ja i x 1750 PSI 1600 PSI 1400 PSI 1800 PSI rm aal Dan 121 110 96 bar 124 bar 1 7 AN 5 4 3000 PS MP T 207 bar Los Lee 25 PSI i j 1 7 bar 1 121 ban E 1 T if A X r m E 7
167. F1 0 45 to 0 5 B F2 0 45 to 0 5 Reverse Bias Test Desired result Positive Lead Negative Lead B M Rises to OL V M B Rises to OL V B F1 Rises to OL V B F2 Rises to OL V F1 B Rises to OL V F2 B Rises to OL V Genie Z 34 22 amp Genie Z 34 22N Part No 36540 Distributed Genie North America Phone 425 881 1800 Toll Free in USA 800 536 1800 Toll Free in Canada 800 426 8089 Fax 425 883 3475 Genie UK Limited Phone 44 1636 614700 Fax 44 1636 614777 Genie China Phone 86 21 62483040 Fax 86 21 62588180 Genie Japan Phone 81 3 3453 6082 Fax 81 3 3453 6083 Genie Australia Pty Ltd Phone 61 07 3375 1660 Fax 61 07 3375 1002 Genie France Phone 33 237 260 999 Fax 33 237 260 998 Genie Holland Phone 31 7051 78836 Fax 31 7051 13993 Genie Latin America Phone 561 994 0380 Fax 561 997 5877
168. G RED ony ORG om E CONTACTOR RED AUXILIARY LIFT PUMP CONTACTOR GRN WHT 3 GRN WHT 87 WHT RED 3 DISCHARGE SET TO LVI GRN WHT 19 WHT RED 6 e PROPORTIONAL FLOW CONTROL RED GRN 2 BRN BLK RED RESET SET TO A 5 8 ras pug BS WHT RED 6 30 gt 7 BLK BP1 BOOM SPEED CONTROLLER BRN JIB FUNCTION 44 1 GRN 1 PLATFROM LEVEL CUTOUT CE OPTION J GRN BLK 1 TB18 RIGHT PLATFORM ROTATE lt BLK JIB WHT JIB JIB 17 MANIFOLD GROUND 0 RN BLK 3 RIGHT 4 PLATFROM ROTATE LEFT ORG 6 GRN 3 JIB 14 E 30 iu l87A ORG 14 il PLATFORM LEVEL UP ORG BLK 15 1 PLATFORM LEVEL DOWN JIB ORG BLU ui TB15 ORG 3 ORG BLK 3 7 BLK 7 PRIMARY BOOM EXTEND PRIMARY BOOM RETRACT EXTEND BLK WHT 8 quu TB8 Bm BLK 3 EXTEND PRIMARY BOOM RETRACT BLK WHT 3 RED 1 PRIMARY BOOM UP 2 PRIMARY BOOM DOWN RED 3
169. H RED WHT SP BRAKE RELEASE 1587 PLATFORM ROTATE SWITCH GRN BLK 1 44 GRN BLK SP JIB DOWN TS58 JIB UP DOWN SWITCH N SEN oar BUE TS59 PLATFORM LEVEL SWITCH 2 2 9 O O ORG RED CR1 ORG RED 1 42 ORG RED CH ORG RED L3 SWITCHED 48V Q ETE P ROVER CEFIIMITSPEED TS60 SECONDARY BOOM UP DOWN SWITCH BLUBLK 190 BLU BLK 1 37 BLU BLK MH STEER RIGHT TS61 PRIMARY BOOM UP DOWN SWITCH 6 PLUA 3 BLU MHI STEER LERT TS62 TURNTABLE ROTATE SWITCH WHT RED 1 32 WHT RED CH JOYSTICK POT LOW WHT BLK 190 480 WHTJBLK al WHTJBLK GH REVERSE TS63 BOOM EXTEND RETRACT SWITCH BRN 52A P1 WHT 1 30 WHT CH FORWARD CB1 CIRCUIT BREAKER CONTROLS 10A P1 BEDAHET REDIMHDCH ZWIRE ROT CB2 CIRCUIT BRKR CONTROLS RETURN 10A RED BLK TILT RED BLK 1 28 TILT ALARM D T 3 Onco HM RED CR3 RED 1 27 RED SP AUXILIARY PUMP SELECT BRAKE RELEASE JACK pO NCO HM 26 LIFT LOCKOUT HM HOURMETER 2 PATERA RIARI CH CHASSIS HARNESS CBI 24 TRACTION CONTROL CBI MH MANIFOLD HARNESS TS51 WHT 7 BLK C23 4 22 BLK CR4 BLK SP 24V TO PLATFORM SP SWITCH PANEL KS1 TB36 TB37 GRNMWHT CR3 19 GRNWHT MH M LIFT PUMP CR CONTROL RELAY Je M wureuesP GRN WHT 3 19 GRN WHT SP LIFT PUMP NO NO GRN BLK 3 18 GRN BLK SP PLAT ROTATE RIGHT 2 BRK REL TRAVEL ALARM 145 RED 134A gt o GRN 3 17 GRN SP PLAT ROTATE LEFT DESCENT ALARM OPTION RED C23 6 4 RED 5 ORG RED 3 16 ORG RED CRS DRIVE
170. HT 4 WHT 3 4 WHT S P R W CURTIS RED WHT 3 3 RED BLK 4 RED BLK 3 2 RD BK S P RD BK D A RED 4 RED 3 1 RED S P D e B A GROUND LIMIT SWITCH BRAKE RELEASE N C EMERGENCY BRAKE RELEASE N C JIB DOWN JIB UP 48V SUPPLY DRIVE COIL PR1 LIMIT SWITCH STEER LEFT STEER RIGHT BRAKE F C REVERSE PR2 FORWARD PR2 BRAKE H S TILT ALARM AUXILIARY POWER PR4 KEY SWITCH POWER POWER TO PLATFORM 12V BATTERY SUPPLY LIFT PUMP PR3 PLATFORM ROTATE RIGHT PLATFORM ROTATE LEFT PLATFORM LEVEL DOWN PLATFORM LEVEL UP DRIVE ENABLE LIGHT DRIVE ENABLE HOUR METER SECONDARY BOOM DOWN SECONDARY BOOM UP HORN BOOM RETRACT BOOM EXTEND LIFT FLOW CONTROL TURNTABLE ROTATE LEFT TURNTABLE ROTATE RIGHT DRIVE FLOW CONTROL PRIMARY BOOM DOWN PRIMARY BOOM UP L K J 1 EE GRN BLK 44 ONC C4 HOUR METER RED 47 ONC E RED 12 _ RED CR1 BRN GROUND _ BLK 7 BLK 22 J1 KS1 TS17 RED WHT 46 T OTe WHT 23 NO NO i A RED427 tiir BLK WHT 8 v WHT RED 6 4 GRN BLK 18 TS15 TS13 GRN 17 CB1 OOO OVO are GRN WHT 19 L 5 4 2 9 7 C RED BLK 2 514 512 ORG BLK 15 O TS19 ORG 14
171. Hold the function enable toggle Switch to either side and move the primary boom toggle switch in the up direction and check the pressure Install a 0 to 5000 PSI 0 to 345 bar pressure gauge at the quick disconnect coupling on the function manifold Z 34 22 before serial less than 3200 PSI Adjust the system relief valve item AB or BB or CR see Repair Section OR repair or replace the cylinder or the cylinder counterbalance valve OR the function manifold could have an internal defect Consult Genie Industries Service Department Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 5 37 Section 5 Troubleshooting Flow Charts First Edition Third Printing Chart 10 Primary Boom Down Function inoperative Be sure key switch is in the appropriate position Be sure the Emergency Stop buttons are pulled out to the on position Be sure the battery packs are properly connected and fully charged Turn key switch to ground controls and pull both Emergency Stop buttons out to the ON position 2 34 22 before serial number 153 and Z34 22N before serial number 304 Move the primary boom toggle switch TS12 in the DOWN direction and check voltage on the wht red 6 wire at the boom function proportional valve coil item AU or BU or 2 34 22 from serial number 153 to 1733 and Z 34 22N from serial number 304 to 2226 Hold the function enable toggle switch to either
172. ING OPTION Q ORG RED 42D RED CH BLK RED 9D 7 U33 yos n 1 L RED WHT 48C 1 ORG MH ORG BLK MH CRS CR10A ICR10B i CONTROL RELAY I D SPARE WIRE LIST RED BLK CH E E RED T CRi SECONDARY 48 POWER BLK 1 CR2 PRIMARY 48V POWER BLKWHT 1 ORGIREDAGK h CR3 AUXILIARY PUMP BLK RED 1 TILT SENSOR CR4 HORN BLUMWHT 1 gt CRS BRAKE RELEASE BLU RED 1 i i CR10A PLATFORM LEVEL CUTOUT CE OPTION GRN WHT 1 pee NOE TCR CN cS ORG 148 ORG BLK 15B i J RED BLK 28D 8 CR10B PLATFORM LEVEL CUTOUT CE OPTION ORG 1 ones ORG BLK 1 BLK BRN CB2 OPTION NUMBERS ORG BLK 3 15 ORG BLK CR10B ORG BLK SP PLATFORM LEVEL DOWN 1 PLATFORM LEVEL CUTOUT ORG 3 14 ORG CR10A ORG SP PLATFORM LEVEL UP CB2 L3 2 FLASHING BEACON 3 DESCENT ALARM foe eo oe Se eee ee tee Soke ose eee se ese cece ee cease 1 BRN 52D T ap BLK CH PLATFORM LEVEL CUTOUT CE VERSION ONLY BRN CH ORG RED 42A 6 33 Genie 7 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 6 Schematics SSS SSS SS SSS SSeS Ground Control Panel Wiring Diagram Z 34 22 after serial number 4799 Z 34 22N after serial number 5619 F E D C B A SWITCH PANEL 1 RD C23 1 TILT SENSOR RD 280 RDWH 34D RD B
173. JIB BOOM UP DOWN TOGGLE SWITCH TS8 PLATFORM LEVEL TOGGLE SWITCH BRN la TS10 SECONDARY BOOM UP DOWN TOGGLE SWITCH 511 PRIMARY BOOM UP DOWN TOGGLE SWITCH 6 TS12 TURNTABLE ROTATE TOGGLE SWITCH TS13 PRIMARY EXTEND RETRACT TOGGLE SWITCH TS15 DRIVE ENABLE TOGGLE SWITCH RED 1 TILT ALARM DRIVE ENABLE LIGHT DP1 L R S BCI BATTERY CHARGE INDICATOR OPTION 11213 4 5 617 8 9 10 7 I uie uu 1 NOTES gt REMOVE JUMPER JP1 FOR CE VERSION 2 REMOVE THIS WIRE WHEN LOAD SENSE OPTION IS REQUIRED c w m w w 2 o 2 o w o w x 9 T m 9 m m i EE Rx S 2 m 2 2 2 2 2 i c i E e m 19 4 d g eau d 2 D D z Z 2 z c n a3 Bg s t E P g n 2 s pee si 5 oss s s B 3 gp o 9 5 9 5 i 9 5 m ES E m X d a i jo e e j do e e 6 38 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 girona SIC LHM gir 5uo air ama WHT First Edition Third Printing n GB Platform Control Box Wiring Diagram 7 34 22 from serial number 2061 to 3577 Z 34 22N from serial number 2871
174. K C1B 2 gk B BR CB2 L3 HM TS63 TS58 1361 oR 9 4 OR 1560 7555 3 5 DESCENT ALARM WIRING OPTION P1 Onc O P Onc O TS59 TS57 TS62 cea BR 52D ap 49 7 Nul 9v ad l lde 19 9 RD WH 48A BR 52A RD 1348 BL RD C2B 1 j GN BK WH BK 19D 48D BR 52A BR C32 12 O O4 P1 NC TERMINAL BASE AND CONNECTORS LL RD C48 1 TS51 RD 134A L45 BK 22A RD C23 6 E G BLWH C1 12 RD 27A OR BK 15A BK 7A BK WH 8A WH RD 6A OR 14A GN BK 18A GN WH 19A GN BK 44A BK 22 GN 43A BK C7 1 7567 F D Op O TS58 L R 1 9 Ou QC RD BK 2A ozz ya Jvgzzd 9 20 9V Xg NO BR HM RD 1A GN 17A WH BK 5A WH 4A eer o S 7 Ol L R Qu J BL BK 11A RD C32 7 12 BR C48 3 OR RD 42A LABEL DESCRIPTI
175. M LEVEL UP PLATFORM LEVEL DOWN 4 TB14 im ORG JIB BLU JIB PLATFORM LEVEL JIB MANIFOLD GROUND PLATFORM LEVEL FUNCTION MANIFOLD GROUND ORG BLK 3 BITB7 PRIMARY BOOM EXTEND PRIMARY BOOM RETRACT PRIMARY BOOM BLK 3 PRIMARY BOOM BLK WHT 3 PRIMARY BOOM UP PRIMARY BOOM DOWN PRIMARY BOOM RED 3 PRIMARY BOOM RED BLK 3 BLU 10 SECONDARY BOOM UP SECONDARY BOOM DOWN BLU BLK 11 SECONDARY BOOM DESCENT ALARM OPTION BLU 3 SECONDARY BOOM dup BLU BLK 3 fe TBS WHT BLK 5 TURNTABLE ROTATE RIGHT TURNTABLE ROTATE LEFT WHT 4 TURNTABLE ROTATE ms BITB4 TURNTABLE E WHTBLK 3 iRicHT WHT 3 BLU WHT 12 RED RED z z cr 8 E B al ORG RED 1 ORG RED WHT 1 WHT BLK 1 GND GND BRN BLK 24V 6 24 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 6 Schematics B M Electrical Schematic Z 34 22 from serial number 3578 to 4799 Z 34 22N from serial number 4261 to 5619 C29JSH RD WH
176. N Turn key switch to ground controls and pull both Emergency Stop buttons out to the ON position Check voltage at the output side of ground controls contact of the key switch 24N 2 34 22 before serial number 153 and Z34 22N before serial number 304 Hold the secondary boom toggle switch TS11 in the UP direction and check voltage at TB6 Z 34 22 after serial number 152 and Z34 22N after serial number 303 Move the function enable toggle switch to either side and hold the secondary boom toggle switch 2 34 22 before serial number 1734 and Z 34 22N before serial number 2227 7511 2 34 22 after serial number 1733 and Z 34 22N after serial number 2226 TS60 in the uP direction and check voltage at TB6 24V Continued on the next page Repair open in the red wire circuit from the Emergency Stop button to the input side of the ground controls contact of the key switch Check to see if the key switch internal cam is activating the ground controls contact yes no Replace the key switch Check the voltage on the red wire at center terminal of each ground control toggle switch Chart 6 Replace the key switch contact for ground controls Repair open in red wire circuit supplying 24V to the center terminal of each ground control toggle switch 24V Repair open in wht red wire circuit with diode from TS60 to TB6 OR replace the diode Part No 36540
177. N 5 52 4 GROUND BRN 2 52 BRN MH BRN SP GROUND WHT 6 WHT 8 50 LS2 LS4 JUNCTION BLK 7 BLK 6 49 LS1 LS2 JUNCTION WHT BLK SP RED WHT CR5 48 RED WHT MH REDMWHT SP BRAKE RELEASE GRN BLK 1 44 GRN BLK SP JIB DOWN GRN 1 43 GRN SP JIB UP ORG RED CR1 ORG RED 1 42 ORG RED CH ORG RED L3 SWITCHED 48V BLK 8 40 ORG CH OFF LIMIT SPEED 190 BLU BLK 1 37 C BLU BLK MH STEER RIGHT 190 BLU 1 36 BLU MH STEER LEFT WHT RED 1 32 3 WHT RED CH JOYSTICK POT LOW WHT BLK 1 31 C1 WHT BLK CH REVERSE WHT 1 30 3 WHT CH FORWARD RED WHT 1 29 RED WHT CH 2 WIRE POT WHT TILT RED BLK 1 28 TILT ALARM RED CR3 RED 1 27 RED SP AUXILIARY PUMP SELECT OPTION 2 23 1 KEYSWITCH POWER RED TILT WHT 2 23 WHT SP KEYSWITCH POWER WHT 7 BLK 2 22 BLK CR4 BLK SP 424V TO PLATFORM TB36 TB37 GRN WHT CR3 19 enwwHrMH urrPuwP M WHT BLK SP GRN WHT 3 19 GRN WHT SP LIFT PUMP GRN BLK 3 18 GRN BLK SP PLAT ROTATE RIGHT GRN 3 17 GRN SP PLAT ROTATE LEFT RED 5 ORG RED 3 16 CO ORG RED CR5 DRIVE ENABLE id ORG BLK 3 15 ORG BLK MH ORG BLK SP PLAT LEVEL DOWN ORG 3 14 ORG MH ORG SP PLAT LEVEL UP WHT 5 BLU RED 3 13 DRIVE ENABLE LIGHT BLK 5 BLU WHT 3 2 1 BLUMHT CH FOOTSWITCH BLU BLK 3 11 BLU BLK MH BLU BLK SP SEC BOOM DOWN BLU 3 10 BLU MH BLU SP SEC BOOM UP BLK RED CR4 BLK RED 3 9 HORN BLK WHT 3 8 BLKWHT MH BLK WHT SP BOOM RETRACT BLK 3 7 BLK MH BLK SP BOOM EXTEND WHT
178. NG with hot or live circuits could cause death or serious injury Remove all rings watches and other jewelry Replace the contactors if any damage is found Part No 36540 Genie 7 34 22 amp Genie Z 34 22N 4 25 Section 4 Scheduled Maintenance Procedures First Edition Third Printing TABLE B PROCEDURES B 20 Replace the Hydraulic Tank Return Filter Genie requires that this procedure be performed quarterly or every 250 hours whichever comes first Perform this procedure more often if dusty conditions exist Replacement of the hydraulic return filter is essential for good machine performance and service life A dirty or clogged filter may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require that the filter be replaced more often ACAUTION Bodily injury hazard Beware of hot oil Contact with hot oil may cause severe burns The hydraulic return filter is located on the bulkhead next to the hydraulic power unit Z 34 22 before serial number 810 and Z 34 22N before serial number 1117 1 Clean the area around the oil filter housing then remove the filter with an oil filter wrench 2 Apply a thin layer of fresh oil to the gasket on the new oil filter Install the new filter 3 Tighten it securely by hand 4 Z 34 22 before serial number 153 and Z 34 22N before serial number 304 Turn the key switch to ground controls and pull out the E
179. NIJ Oo AY Oo Oy co A NIN m RIJN NI RES NIO yo o or oo AR 6 83 Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 2 5 Section 2 Specifications First Edition Third Printing J Xsn J s sm n This page intentionally left blank 2 6 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section Scheduled Maintenance Inspections Scheduled Maintenance Inspections 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 hourly quarterly annually and every 2 years as specified on the Maintenance Inspection Report Failure to properly complete each AWARNING inspection when required could cause death serious injury or substantial machine damage Immediately tag and remove from service damaged or malfunctioning machine Repair any machine damage or malfunction before operating machine Machines that have been out of service for a period longer than 3 months must complete the hourly and quarterly inspections About This Section The Schedule There are five types of maintenance inspections that must be performed according to
180. NTT 1 Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 6 3 Section 6 Schematics First Edition Third Printing Load Sensor Option Diagram 7 34 22 before serial number 1734 7 34 22 before serial number 2227 LABEL DESCRIPTION e VES E VA P2 EMERGENCY STOP BUTTON HORN BUTTON DP1 DRIVE CONTROLLER 1 BOOM SPEED CONTROLLER ol LORD crs E 51 TURNTABLE ROTATE SWITCH ep a TS2 SECONDARY BOOM SWITCH TS3 PRIMARY BOOM SWITCH LOAD SENSOR se TS4 EXTEND RETRACT SWITCH 21944 5 16 7 8 91 10 T PLATFORM LEVEL SWITCH EDIK 756 PLATFORM ROTATE SWITCH 0 TS7 JIBSWITCH NES TS8 AUXILIARY SWITCH 159 DRIVE ENABLE SWITCH RESET DISCHARGE E L1 DRIVE ENABLE LIGHT AE BCI BATTERY CHARGE INDICATOR SETTO N TS18 LIFT DRIVE SELECT OPTION 12 OVERLOAD LIGHT OPTION Oruse x x y Q e
181. ON P1 EMERGENCY STOP BUTTON KS1 KEY SWITCH TS51 AUXILIARY TOGGLE SWITCH TS55 FUNCTION ENABLE TOGGLE SWITCH TS57 PLATFORM ROTATE TOGGLE SWITCH TS58 JIB UP DOWN TOGGLE SWITCH TS59 PLATFORM LEVEL TOGGLE SWITCH TS60 SECONDARY BOOM UP DOWN TOGGLE SWITCH TS61 PRIMARY BOOM UP DOWN TOGGLE SWITCH TS62 TURNTABLE ROTATE TOGGLE SWITCH TS63 BOOM EXTEND RETRACT TOGGLE SWITCH CB1 CIRCUIT BREAKER CONTROLS 10A CB2 CIRCUIT BREAKER CONTROLS RETURN 10A HM HOURMETER CH CHASSIS HARNESS MH MANIFOLD HARNESS SP SWITCH PANEL CR CONTROL RELAY A2 TRAVEL ALARM DESCENT ALARM OPTION 6 PLATFORM OVERLOAD CE OPTION L3 CONTROLLER STATUS LED L45 PLATFORM OVERLOAD LED C32 U33 PLATFORM OVERLOAD OPTION BL 10A Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 6 34 First Edition Third Printing Section 6 Schematics Ground Control Panel Wiring Diagram 7 34 22 after serial number 4799 Z 34 22N after serial number 5619 First Edition Third Printing Section 6 Schematics 5 Ground Control Terminal Strip Wiring Diagram Z 34 22 after serial number 4799 Z 34 22N after serial number 5619 M L K J H G F E D C B A
182. OR the steer brake function manifold could have an internal defect OR consult Genie Industries Service Department Chart 26 Repair or replace the steer microswitch OR consult Genie Industries Service Department Replace steer right directional valve coil Check for mechanical restrictions keeping steer right function from moving OR the 0 085 orifice item O is plugged OR repair or replace steer cylinder OR consult Genie Industries Service Department Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 5 97 Section 5 Troubleshooting Flow Charts First Edition Third Printing Chart 27 Steer Right Function inoperative Z 34 22 after serial number 1733 and Z 34 22N after serial number 2226 Be sure key switch is in the appropriate position Be sure the Emergency Stop buttons are pulled out to the on position Be sure the battery packs are properly connected and fully charged Be sure all other functions operate normally Turn key switch to platform controls and pull both Emergency Stop buttons out to the ON position Press down the foot switch and Press down the foot 20V Repair open in blu blk 1 wire circuit from drive switch and press the more steer rocker switch in the RIGHT direction Check voltage at terminal 10 on the drive controller controller terminal 10 to TB37 press the steer rocker switch on the drive
183. PR2 Press down the foot switch and move the drive controller in the FORWARD direction and check voltage on TB31 Press down the foot switch and move the drive controller in the FORWARD direction and check voltage on wht blk 1 wire on micro switch on the drive controller Repair or replace micro switch on the drive controller OR drive controller cams are out of adjustment Consult Genie Industries Service Department Remove wht blk 31 and ground wires from PR2 coil and check resistance of forward Coil Repair or replace PR2 contacts OR repair open in ground wire circuit OR consult Genie Industries Service Department Repair open in white blk 31 wire circuit from to the forward contactor Repair open in wire circuit from wht blk 1 wire on micro switch on drive controller to TB31 0 or infinite ohms Repair or replace PR2 5 120 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 5 Troubleshooting Flow Charts Chart 32 Drive Reverse Turn key switch to Remove wht 30 and E j platform controls and ground wires from PR2 Function pull both Emergency coil and check onis Repair or replace PR2 inoperative Stop buttons out to the of reverse coil Z 34 22 before serial number 1734 and Z 34 22N before serial number 2227 Be sure key switch is in the appropriate position Be sure the Emergency Sto
184. Printing Section 5 Troubleshooting Flow Charts CHART 28 Press down the foot Repair open in positive switch and move the cable from 1 to drive controller in the terminal B on the motor FORWARD direction and controller check voltage at terminal B on the motor controller Continued from the previous page 48V or more Press down the foot Repair open in positive switch and move the cable from 1 to drive controller in the terminal A1 on the left FORWARD direction and drive motor check voltage at A1 terminal on the left drive motor 48V or more Press down the foot Repair open in org blk Switch and move the wire circuit from TB41 to drive controller in the terminal 1 on the motor FORWARD direction and controller check voltage on terminal 1 on the motor controller 20V or more Continued on the next page Part No 36540 Genie 2 34 22 amp Genie Z 34 22N 5 103 Section 5 Troubleshooting Flow Charts CHART 28 Continued from the previous page to 5V Continued on the next page Check voltage at terminal 3 on the motor controller Voltage should ramp up from OV good Press down the foot switch and slowly move the drive controller from neutral to full stroke in the FORWARD direction and check voltage on TB3 Voltage should ramp up from OV to 5V bad 2 34 22 before serial number 153 and Z34 22N before serial number 304 Press
185. RED 3 6 WHT RED MH WHT RED SP BOOM FUNCTION WHT BLK 3 5 WHT BLK MH WHT BLK SP TURN ROTATE RIGHT WHT 3 4 WHT MH WHT SP TURN ROTATE LEFT REDMHT CR1 REDMWHT 3 3 48V RELAY COIL PWR RED BLK 3 2 RED BLK MH RED BLK SP PRIMARY BOOM DOWN RED 3 1 RED MH RED SP PRIMARY BOOM UP D SEE OPTIONAL WIRING L DENOTES TEST PORT GRN WHT 19C ORGED CH RED 27D GRN WHT CH BLK 22B 1 le a n F BRN 52A RED WHT TB3D BLK RED HORN ORG RED 42D RED CH BLK RED 9D oe EE ee ee rte cs ped Su RED WHT 48C ORG MH ORG BLK MH 5 1 TOA 108 RED BLK CH i e Tee Lr RED 6 ORG RED 16A H ORG 14B ORG BLK 15B ORG 6 ORG BLK 3 15 ORG BLK CR10B ORG BLK SP PLATFORM LEVEL DOWN LE ORG 3 14 ORG CR10A ORG SP PLATFORM LEVEL UP RED WHT A2 BRN WHT BLK 19D 48D BRN 52A ne OY NC OF 1 RED Ji TS51 RED WHT 48A SO ks 6 0 No NO WHT 23A 5 BLK 22A F RED v RED 27A BLK 7A v BLK WHT 8A WHT RED 6A GRN BLK 18A TS57 GRN 17A 2 563 CB1 GRN WHT 19A L R R Hj RED BLK 2A RED 1A RED TS59 TSet ORG BLK 15A Op TS55 ORG 14A Ou Lou WHT BLK 5A 2 WHT 4A TS
186. RIMARY BOOM BED f ges S YBLKH2 Ly PRIMARY BOOM DOWN DOWN RED 3 PRIMARY BOOM i 2 RED BLK 3 A DOWN e 4 UP BLUSO y SECONDARY BOOM UP SECONDARY BOOM Nr SECONDARY BOOM DOWN DOWN n DECENT ALARM i Lo OPTION UP D Li SECONDARY BOOM 2 BLU BLK 3 DOWN maur WHT BLK 5 7 7 TURNTABLE ROTATE RIGHT TURNTABLE ROTATE 2 T WHT 4 TURNTABLE ROTATE LEFT Pa LEFT RIGHT WHT BLK 3 TURNTABLE ROTATE WHT 3 E E LEFT liz gt EWC 185 ET 1 x m WHT 2 9 c 26 8 2 BLK RED 3 BLK RED 9 HORN COIL SE RED BLK 1 B RED BLK 28 NP LI gt i whe WHT 23 ae TILT LEVEL SENSOR 8 RI BLK 2 e 2 2 3 FLASHING BEACON AE OPTION o 5 I E 58 4 za 6 2 sal gu tr RED R1 oot gt HORN 9 WHT 40 BLK 49 BLK 49 WHT 23 a iu er x NE 5 LP uic g Las gI ZIE ORG BLK 41 lt DRIVE MASTER 46 EK RELAY z z ORG 1 Lr Lu lt J O05 hi of ORG BLK 41 uc RED WHT 3 RED WHT 3 il 2h DRIVE MOTOR SYSTEM ORGRED Ff E PaL lt is BER C ER 1 PRIMARY x C PUMP MOTOR Q PEE c c DET ai rs RED 20 x EP Cam
187. TERY CHARGE INDICATOR LIFT DRIVE SELECT OPTION HORN BUTTON DRIVE CONTROLLER amp C amp amp amp O RESET DISCHARGE Q O SET TO A SET TO N RED 2 JIB LABEL P2 P3 DP1 BP1 TS1 TS2 TS3 TS4 55 56 57 58 59 L1 BCI TS18 ORG RED 3 RED BLK 1 BRN WHT FS CR3 COIL ORG RED 1 BLU WHT 3 WHT FS WHT BLK 3 WHT 3 BLU BLK 3 BLU 3 GRN BLK 44 1 GRN 43 1 GRN WHT 3 First Edition Third Printing Platform Control Box Wiring Diagram 7 34 22 before serial number 1734 Z 34 22N before serial number 2227 Section 6 Schematics TS9 TS1 TS2 TS7 OOO Lago iD THRESHOLD lt BLK RED RED TS5 OEC LEN 1 153 WHT RED 3 ORG BLK 3 ORG 3 RED BLK 3 RED 3 BRN 2 BLK WHT 3 BLUE JIB GRN BLK 3 ORG JIB GRN 3 L1 Sz TS4 S v OO TS6 EN gt O J TS18 OPTION Q O O BLK 3 BLU RED 3 BLK RED 3 ORG RED 42 1 WHT 30 1 WHT BLK 31 1
188. Test or Replace the Hydraulic Oil Every 250 hours perform the following maintenance procedure B 20 Replace the Hydraulic Tank Return Filter E Part No 36540 Genie Z 34 22 amp Genie Z 34 22N Section Scheduled Maintenance Inspections First Edition Third Printing MAINTENANCE TABLES Tools are New parts engine engine service required required required required suggested C 1 Check the Primary Boom Wear Pads C 2 Check the Turntable Rotation Bearing Bolts C 3 Check the Free wheel Configuration C 4 Grease the Turntable Rotation Bearing and Worm Drive Gear C 5 Replace the Drive Hub Oil C 6 Bleed the Platform Rotator Ea A V aadd Table D D 1 Test or Replace the Hydraulic Oil 2 2 Grease the Steer Axle Wheel Bearings 3 4 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section Scheduled Maintenance Inspections Maintenance Inspection Report Model Serial number Date Hour meter Machine owner Inspected by print Inspector signature Inspector title Inspector company Instructions Make copies of this page to use for each inspection Select the appropriate checklist s for the type of inspection to be performed Daily Inspection A Hourly Quarterly Inspection A B Annual Inspection A B C 2 Year Inspection A B C D Place a check in the appropriate box after
189. This Section When a malfunction is discovered the flow charts in this section will help a service professional pinpoint the cause of the problem To use this section basic hand tools and certain pieces of test equipment are required voltmeter ohmmeter pressure gauges The location of terminals mentioned in this section can be found on the appropriate electrical or hydraulic schematics provided in Section 6 Schematics Since various degrees of a particular function loss may occur selecting the appropriate flow chart may be troublesome When a function will not operate with the same speed or power as a machine in good working condition refer to the flow chart which most closely describes the problem On Z 34 22 models after serial number 1733 and Z 34 22N models after serial number 2227 an LED will flash a fault code to aid in troubleshooting This LED is mounted on the ground controls panel located behind the side cover on the ground controls side General Repair Process Malfunction discovered service Retum to problem Identify Troubleshoot symptoms problem still exists Perform repair solved 5 2 Genie 7 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 5 Troubleshooting Flow Charts Fault Code Chart Z 34 22 after serial number 1733 and Z 34 22N after serial number 2226 Fau
190. Tr E m Bom E m 2 o e 9 g 1 210 E o V 2 ja mE e jo o lj e e 2 EA d ja e e e Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 6 40 First Edition Third Printing Section 6 Schematics Platform Control Box Wiring Diagram 7 34 22 after serial number 3577 Z 34 22N after serial number 4260 Section 6 Schematics Hydraulic Schematic First Edition Third Printing mE 7 34 22 before serial number 674 Z 34 22N before serial number 935 A B C D F G J K L M N 5 BRAKES CYLINDER I 0 085 2 2 15 mm x JIB BOOM 0 025 CY END E CYLINDER 0 63 mm PLATFORM LEVEL GHEICE DEL
191. VEL T 89 6 CIBPRRGRIBK C4B6 CUT OUT OPTION i g T 1 eje C4P 5 C17PRLGR C4B 5 81 amp 98 i gt a OR n 4 PLATFORMLEVEL 9 Z E d UPCOIL Sz Eg 4 1 Yi 4 PLATFORM LEVEL 5 E 55 DOWN g 5 DOWN COIL T g z 1 au MALA 1 lt 1 2 8t lt 2 j gt zu 2 C14PLU OR C4B2 amp o 1 C4P 3 C15PLD OR BK C4B 3 i z u B 3 2 gr BK lA 4 BOOM EXTEND z x 2 lt 28 mE ni 4 8 6 9 8 25 B i 5 iu 1 lt 7 C7PBE C3B 7 3 s 1 C8PBR BKWH C3B 8 RD PRIMARY 4 E 7 1 BOOM UP a 1 m 4 PRIMARY 9 29 DOWN BOOM DOWN a 1 aa lt wa E 1 ge amp 20 TQ uP C3P 1 C1PBU RD C3B 1 a gt i 8 C3P 2 C2PBD C3B 2 2 5 mn 5 up BL SECONDARY amp g 5 amp BOOM UP m a BLEK SECONDARY 8 DOWN BOOM DOWN E lt 1 2 E J hi 500 6 98 4 DESCENT ALARM Su uo 10 CiOSBUBL C3B 10 OPTION E Te ee 7 7 me rH CaP 11 C11SBD BL BK C3B M a 9 g 4 TE
192. X PWR PR4 RED TILT ALARM WHT LS1 23 WHT 2 WHT SP KEYSWITCH PWR 22 BLK 2 BLK SP PWR TO PLATFORM RED CH 20 RED SP 12V BATT SUPPLY 5 H GRN WHT PS 19 TB36 amp 37 BLU BLU BLK GRN WHT CR2 CR3 GRN WHT 3 19 GRN WHT SP LIFT PUMP PR3 GRN BLK 3 18 GRN BLK SP PLAT ROTATE RIGHT GRN 3 17 GRN SP PLAT ROTATE LEFT ORG RED 3 16 RED LS3 ORG BLK CR4 ORG BLK 3 15 ORG LS2 ORG BLK SP PLAT LEVEL DOWN ORG CR4 ORG 3 14 ORG LS2 gt OPT ORG SP PLAT LEVEL UP BLU RED 3 13 WHT LS3 DRIVE ENABLE LIGHT 6 BLU WHT 3 12 BLK LS3 RED SP HM DRIVE ENABLE HOUR METER BLU BLK MH BLU BLK 3 11 BLU BLK A3 BLU BLK SP SECONDARY BOOM DOWN BLU MH BLU 3 10 BLU SP SECONDARY BOOM UP BLK RED 3 9 BLK RED CR1 HORN BLK WHT MH BLK WHT 3 8 BLK WHT SP BOOM RETRACT BLK MH BLK 3 7 BLK SP BOOM EXTEND WHT RED MH WHT RED 3 6 WHT RED SP 3 LIFT FLOW CONTROL 7 WHT BLK MH WHT BLK 3 5 WHT BLK SP TURNTABEL ROTATE LEFT WHT MH WHT 3 4 WHT SP TURNTABEL ROTATE RIGHT RED WHT CH RED WHT 3 3 DRIVE FLOW CONTROL RED BLK MH RED BLK 3 2 RED BLK A3 RED BLK SP PRIMARY BOOM DOWN RED MH RED 3 1 RED SP PRIMARY BOOM UP D C B A 8 Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 6 30 First Edition Third Printing Section 6 Schematics pmamE o Ground Control Panel Wiring Diagram 7 34 22 from serial number 153 to 1733 Z 34 22N from serial number 304 to 2226 Section 6 Schematics First Edition Thir
193. XILIARY PRIMARY P1 G1 BRAKE pe 2 L1 L2 TRI G3 TR2 Sci Sc2 PCi PC2 EXT RET 21r T o No E rie eM 0 646 inch cc eS H pr 7 221 5 Mmm I o z P 0 EL oC 0 0 4 4 nx L 1600 PSI 1400 PSI Yaoi Psi ES om 1 1011 Ta 110 bar 110 bar 3000 PSI 1100 PSI cr Hoe e as i L3 t X LI i 1 n HX UTER 10 MICRON 1 14 mm IT 100 MESH AX 1 cx Y 0 8 GPM 1 5 GPM 7 cv cu cv 8 i 3 L min 5 7 L min D 1 1 1 HYDRAULIC TANK DD t d d ti added aftar serial number Z 34 22N 3517 i i 0 035 inch im m 2 4 4 4 n n 4 4 n Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 6 44 First Edition Third Printing Section 6 Schematics Hydraulic Schematic 7 34 22 from serial number 2006 to 2900 Z 34 22N from serial number 2772 to 3532 First Edition Third Printing Section 6 Schematics Hydraulic Schematic Z 34 22 after serial number 2900 Z 34 22N after serial number 3532 N M L K J H G F E D C B A JIB BOOM LI CYLINDER PLATFORM ROTATE
194. after serial number 2226 Hold the function enable toggle switch to either side and move the turntable rotate toggle switch in the LEFT direction and check voltage on the wht 4 wire on the turntable rotate directional valve coil item CD Continued from page 60 24V Continued on the next page Z 34 22 before serial number 153 and Z34 22N before serial 24V number 304 Move the turntable rotate toggle switch in the LEFT direction and check voltage at TB4 Z 34 22 after serial number 152 and Z34 22N after serial number 303 Hold the function enable toggle switch to either side and move the turntable rotate toggle switch in the LEFT direction and check voltage at TB4 Turn key switch to oV Repair open in wht 3 platform controls and wire circuit to TB5 pull both Emergency Stop buttons out to the ON position With the boom function speed controller turned to 9 press down the foot switch and move the turntable rotate toggle switch Z 34 22 before serial number 1734 and Z 34 22N before serial number 2227 TS4 Z 34 22 after serial number 1733 and Z 34 22N after serial number 2226 TS13 in the LEFT direction Check voltage at TB5 Repair open in wht blk 4 wire circuit from TB4 to turntable rotate left directional valve coil OR repair open in brn ground wire circuit to manifold 24V Troubleshoot the turntable rotate toggle switch OR replace diode on toggle switch OR repair open in wht
195. amp Genie Z 34 22N Section 7 Repair Procedures First Edition Third Printing rm M A ee scii PRIMARY BOOM COMPONENTS 10 Support the primary boom lift cylinder with straps or ropes to restrict it from swinging freely 11 Remove the pin retaining fastener from the primary boom lift cylinder barrel end pivot pin Do not remove the pivot pin 12 Use the overhead crane to lift the primary boom 1 inch 2 5 cm This will relieve pressure on the barrel end pivot pin 13 Place a rod through the barrel end pivot pin and twist to remove the pin Crushing hazard The primary ACAUTION boom lift cylinder will swing down if itis not properly supported when the barrel end pivot pin is removed 14 Attach and secure the rod end of the primary boom lift cylinder to an overhead crane or similar lifting device Carefully lower the straps and allow the primary boom lift cylinder to slowly swing down 15 Carefully remove the cylinder from the machine ACAUTION Crushing hazard The primary boom lift cylinder may become unbalanced and fall if it is not properly supported when the rod end pivot pin is removed 7 24 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 7 Repair Procedures 4 4 Extension Cylinder The extension cylinder extends and retracts the primary boom extension tube The extension cylinder is equipped with counterbalance valves to preve
196. and unusual noise Z 34 22N before serial number 304 and Z 34 22 before serial number 153 1 Turn the key switch to ground controls and pull out the Emergency Stop button to the position at both the ground and platform controls Result Beacon if equipped should flash 2 Attempt to activate each boom and platform function toggle switch Result All machine functions should operate through a full cycle The descent alarm if equipped should sound while the boom is lowering 3 Push in the Emergency Stop button to the position Result No function should operate The machine should stop TABLE A PROCEDURES Turn the key switch to platform controls and pull out the Emergency Stop button to the on position at both the ground and platform controls Result Beacon if equipped should flash Move the lift drive select toggle switch to the lift position if equipped Press down the foot switch and operate each machine function through a full cycle Result All machine functions should operate smoothly Push in the Emergency Stop button to the position Result No function should operate The machine should stop As a safety feature selecting and operating the ground controls will override the platform controls including the Emergency Stop button Machines equipped with Platform Level Control Disable Function The platform level toggle switch will not operate when the primary
197. at TB22 ov 24V Check voltage at the input side of the platform OV Emergency Stop button contact 24V Check voltage at the output side of platform Emergency Stop button contact 24V Continued on the next page Section 5 Troubleshooting Flow Charts Repair open in red wire circuit from Emergency Stop button to the key switch Check to see if the key switch internal cam is activating the platform Chart 8 Replace the key switch contact for platform controls controls contact no Replace the keyswitch Repair open blk 22 wire circuit from key switch to TB22 Repair open in blk 2 wire circuit from TB22 to the platform Emergency Stop button OR repair open in brn ground wire circuit from 52 to the platform Check to see if the Emergency Stop button Replace the platform Emergency Stop button is activating the contact contact no Replace the platform Emergency Stop button Part No 36540 Genie Z 34 22 amp Genie Z 34 22N Section 5 Troubleshooting Flow Charts CHART 8 Continued from the previous page Turn key switch to platform controls and pull both Emergency Stop buttons out to the ON position Press down the foot switch and check voltage at terminal 6 on the drive controller 24V Press down the foot switch and check voltage at the center terminal of each function toggle switch 24V Press
198. aulic rotation 0 to 207 bar pressure less than motor OR platform gauge at the quick 2800 psi rotate jib function disconnect coupling on manifold could have an the boom function internal defect Consult manifold and activate Genie Industries Service the platform rotate LEFT Department function Check for mechanial restrictions keeping platform rotate LEFT function from moving OR the 2 34 22 before serial number 1734 and Z 34 22N before serial number 2227 0 030 orifice item W 2 34 22 after serial number 1733 and Z 34 22N after serial number 2226 0 025 orifice item W could be plugged OR repair hydraulic rotation motor OR consult Genie Industried Service Department Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 5 83 Section 5 Troubleshooting Flow Charts Chart 21 Platform Rotate Right Function inoperative Be sure key switch is in the appropriate position Be sure the Emergency Stop buttons are pulled out to the on position Be sure the battery packs are properly connected and fully charged Turn key switch to ground controls and pull both Emergency Stop buttons out to the ON position 2 34 22 before serial number 153 and Z34 22N before serial number 304 Move the platform rotate toggle switch TS15 in the RIGHT direction and check the voltage on the wht red 6 wire at the boom function proportional valve coil item AU Z 34 22 from serial number 153 to 1733 an
199. beginning of this section to determine the cause of the fault Refer to Chart 34 Check for proper activation of primary boom limit switch LS2 OR replace LS2 contact OR replace LS2 Check for proper activation of secondary boom limit switch LS4 OR replace LS4 contact OR replace LS4 Check for proper activation of primary boom extend limit switch LS1 OR replace LS1 contact OR replace 1151 5 126 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Drive Enable System Is Malfunctioning Z 34 22 before serial number 1734 and Z 34 22N before serial number 2227 Be sure the machine is in the stowed position with the turntable rotated so the boom is in between the non steer wheels Be sure all other functions operate normally Turn key switch to platform controls and pull both Emergency Stop buttons out to the ON position Press down the foot switch and check voltage at TB12 Press down the foot switch and check voltage at TB16 Press down the foot switch and check voltage at terminal on drive controller Rotate the boom past either non steer wheel and check voltage on 16 Continued on the next page Section 5 Troubleshooting Flow Charts Chart 37 Repair open in blu wht 3 wire circuit from TB12 to center pole of TS9 Repair open in blk 12 wire circuit from TB12 through normally closed contact of LS3 to TB16
200. ber 304 Move the jib toggle switch in the DOWN direction and check the voltage at TB6 2 34 22 after serial number 152 and 234 22 after serial number 303 Hold the function enable toggle switch to either side and move the jib toggle switch in the DOWN direction and check the voltage at TB6 ov Turn key switch to platform controls and pull both Emergency Stop buttons out to the ON position With the boom function speed controller turned to 9 press down the foot switch and move the jib toggle switch Z 34 22 before serial number 1734 and Z 34 22N before serial number 2227 57 Z 34 22 after serial number 1733 and Z 34 22N after serial number 2226 TS8 in the DOWN direction Check voltage at TB6 Troubleshoot jib function toggle switch on ground controls OR repair open in wht red 6 wire circuit from toggle switch to TB6 OR consult Genie Industries Service Department 20V or more Chart 23 Repair open in wht red 6 wire circuit from TB6 to boom function proportional valve coil OR repair open in brn ground wire circuit to boom function proportional valve coil Troubleshoot jib function toggle switches on ground and platform controls OR repair open in wht red 6 wire circuit from ground controls toggle switch to TB6 and from platform controls toggle switch to red wire on boom rotary speed controller OR consult Genie Industries Service Department If voltage to TB6 from toggle swi
201. ber 304 Move the turntable rotate toggle Switch in the RIGHT direction and check the pressure 2 34 22 after serial number 153 and 2 34 22 after serial number 304 Hold the function enable toggle switch to either side and move the turntable rotate toggle switch in the RIGHT direction and check the pressure Adjust the system relief valve see Repair Section item AB or BB or CR OR repair or replace the turntable rotation motor OR function manifold could have an internal defect Consult Genie Industries Service Department function inoperative less than 3200 PSI Replace the turntable rotate right directional valve Replace defective directional valve Check for mechanical restrictions keeping the turntable rotate left function from operating OR repair or replace the turntable rotation motor OR consult Genie Industries Service Department 5 68 Genie 2 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 5 Troubleshooting Flow Charts All Platform Level Functions Inoperative Be sure key switch is in the appropriate position Be sure the Emergency Stop buttons are pulled out to the oN position Be sure the battery packs are properly connected and fully charged Z 34 22 before serial number 153 and Z34 22N before serial number 304 Remove both hydraulic hoses from the function manifold ports C1 and C2 Plug the hoses and
202. boom function toggle switch at the ground controls Z 34 22 after serial number 152 and Z 34 22N after serial number 303 Hold the function enable switch to either side and move any boom function toggle switch at the ground controls Result If the pressure gauge reads 3200 psi 220 bar immediately stop The pump is good Result If pressure fails to reach 3200 psi 220 bar Z 34 22 before serial number 153 and Z 34 22N before serial number 304 the external relief valve setting is incorrect or the pump is faulty and will need to be serviced or replaced Z 34 22 from serial number 153 to 809 and Z 34 22N from serial number 304 to 1116 the internal relief valve setting is incorrect or the pump is faulty and will need to be serviced or replaced Z 34 22 after serial number 809 and Z 34 22N after serial number 1116 the relief valve setting on the function manifold item YY is incorrect or the pump is faulty and will need to be serviced or replaced Remove the pressure gauge and reconnect the hydraulic hose 7 38 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 7 Repair Procedures How to Remove the Main Function Pump Z 34 22 before serial number 810 and Z 34 22N before serial number 1117 1 Remove the support angle from the side of the hydraulic power unit 2 Remove the mounting fasteners from the hydraulic tank and lower the tank 3 Remove the pump mounting bo
203. ccess the drive hub drive chassis mounting bolts 1 Disconnect the battery packs from the When removing a hose assembly machine or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation 2 Remove the chassis cover from the non steer end of the machine 3 Tag and disconnect the power cables from the Refer to Section Two Hydraulic drive motor Hose and Fitting Torque Specifications AWARNING Electrocution burn hazard Contact with electrically charged circuits 1 Remove the drive motor See 11 1 could result in death or serious How to Remove a Drive Motor injury Remove all rings watches 2 Disconnect the hydraulic hose from the brake and other jewelry and plug it Cap the fitting on the brake AWARNING Bodily injury hazard Spraying 5 Guide the drive motor shaft out of the brake hydraulic oil can penetrate and and remove the drive motor from the machine 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 drive motor mounting fasteners 3 Chock the steer wheels 4 Loosen the wheel lug nuts on the wheel of the drive hub to be removed Do not remove the lug nuts 7 62 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 7 Repair Procedures m Q ys c ro n
204. cell displays a specific machine performance and operational safety gravity of less than 1 026 the battery must be Improper fluid levels or damaged cables and replaced connections can result in engine component damage and hazardous conditions 6 Check the battery acid level of the battery If needed replenish with distilled water to the Bodily injury hazard Batteries bottom of the battery fill tube Do not overfill AWARNING contain acid Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda Check each battery pack and verify that the and water batteries are wired correctly Install the battery vent caps Electrocution burn hazard Contact Connect the battery packs to the machine AWARNING with hot or live circuits could result s in death or serious injury Remove all rings watches and other jewelry Perform this test after fully charging the batteries 1 Puton protective clothing and eye wear 2 Disconnect the battery packs from the machine 3 Be sure the battery cable connections are free of corrosion 4 Be sure the battery hold down and cable connections are tight 4 12 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 4 Scheduled Maintenance Procedures B 2 Inspect the Electrical Wiring Maintaining electrical wiring in good condition is essential to safe operation and good machine perf
205. ch and press the steer rocker switch on the drive controller in the LEFT direction Check voltage at TB36 20V or more Press down the foot switch and press the steer rocker switch in the LEFT direction Check voltage at TB19 20V or more Press down the foot switch and press the Steer rocker switch in the LEFT direction Check voltage on the blu 36 wire at the steer left directional valve coil item CJ 20V or more Press down the foot switch and press the Steer rocker switch in the LEFT direction Check voltage at terminal 9 on the drive controller 20V or more Repair open in blu 1 wire circuit from drive controller terminal 9 to 36 Repair open in grn wht 119 wire circuit with diode from TB36 to TB19 OR replace the diode Repair open in blu 36 wire circuit from TB36 to the steer left directional valve coil OR repair open in brn ground wire circuit to the function manifold Chart 25 Repair or replace the steer microswitch on the the drive controller OR consult Genie Industries Service Department 0 or infinite ohms Replace steer left directional valve coil Disconnect the blu 36 wire to the steer left directional valve coil Test the resistance of the valve coil See Repair Section 23 to 25 ohms Continued on the next page Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 5 95 Section 5 Troubleshooting Flow Charts First E
206. ch in the RETRACT direction Check the voltage at TB8 Turn key switch to platform controls and pull both Emergency Stop buttons out to the ON position With the boom function speed controller turned to 9 press down the foot switch and move the primary boom extend retract toggle switch in the RETRACT direction Check voltage at TB8 Troubleshoot the primary boom extend retract toggle switch on ground controls OR replace diode on toggle switch OR repair open in blk wht 8 wire circuit from toggle switch to TB8 OR replace toggle switch CHART 14 Repair open in blk wht 8 wire circuit from TB8 to primary boom retract directional valve coil OR repair open in brn ground wire circuit to the manifold Repair open in blk wht 8 wire circuit to TB8 Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 5 57 Section 5 Troubleshooting Flow Charts First Edition Third Printing CHART 14 0 or infinite ohms Disconnect the blk wire to the primary boom Replace the primary extend directional valve boom extend directional coil Test the resistance valve coil of the valve coil See Repair Section Continued from the previous page Exchange the primary boom extend and retract directional valves 2 34 22 before serial number 1734 and 2 34 22 before serial number 2227 item
207. cluding tank 26 5 liters Z 34 22 after serial number 808 and Z 34 22N after serial number 1115 Hydraulic tank capacity 4 gallons 15 1 liters Hydraulic system 6 gallons including tank 22 7 liters A 5 Check for Hydraulic Leaks Detecting hydraulic fluid leaks is essential to operational safety and good machine performance Undiscovered leaks can develop into hazardous situations impair machine functions and damage machine components 1 Inspect for hydraulic oil puddles dripping or residue on or around the following areas Hydraulic tank filter fittings hoses andturntable surface Compartments hydraulic power unit auxiliary power unit pumps suction filter fittings hoses and turntable surface All hydraulic cylinders All hydraulic manifolds Primary secondary and jib booms Theunderside of the turntable The underside of the drive chassis Ground area under the machine Genie 7 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 4 Scheduled Maintenance Procedures A 6 Test the Platform and Ground Controls Testing the machine functions and the Emergency Stop buttons for malfunctions is essential for safe machine operation An unsafe working condition exists if any function fails to operate properly or either Emergency Stop button fails to stop all the machine functions Each function should operate smoothly and be free of hesitation jerking
208. coil item Test the resistance of red 1 wire circuit from Press down the foot the proportional valve Z 34 22 before serial switch and move the coil item N See Repair number 153 and drive controller in the Section Z34 22N before serial FORWARD direction until number 304 terminal the 1 2 stroke micro infini A on drive controller to switch activates Does 0 or infinite ohms TB32 the amperage increase Z 34 22 from serial proportionally from 0 10 number 153 to 1733 amps to 0 90 amps at and Z 34 22N from 1 2 stroke of drive serial number 304 to controller 2226 terminal B on drive controller to TB32 OR repair open in the ground wire circuit to the proportional brake release valve coil OR repair or replace drive controller OR consult Genie Industries Service Department Replace brake proportional valve coil Continued on the next page 5 108 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 5 Troubleshooting Flow Charts CHART 28 Press down the foot Install a 0 to 3000 psi 0 _ Replace pressure switch switch and move the to 207 bar pressure item K OR consult drive controller in the gauge at the quick Genie Industries Service FORWARD direction to full disconnect coupling on Department stroke and check the function manifold voltage at TB19 Press down the foot switch and move the drive controller in the FORWARD direction and check pr
209. condary boom toggle switch OR replace diode on toggle switch OR repair open in blu 10 wire circuit from toggle switch to TB10 OR replace toggle switch 5 44 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 5 Troubleshooting Flow Charts 11 Continued from the Disconnect the blu 10 nite ravioli pade wire to the secondary Bf Replace the secondary P page boom up directional boom up directional valve coil Test the valve coil resistance of the valve coil See Repair Section Exchange the secondary and primary boom directional valves 2 34 22 before serial number 1734 and Z 34 22N before serial number 2227 items D and E 2 34 22 after serial number 1733 and Z 34 22N after serial number 2226 items AB and AC Activate the secondary boom uP function function inoperative Install a 0 to 5000 PSI 0 Adjust the system relief to 345 bar pressure valve see Repair gauge at the quick Section disconnect coupling on Z 34 22 before serial the function manifold number 1734 and Z 34 22 before serial Z 34 22N before serial number 153 and number 2227 item B Z34 22N before serial less than 2 34 22 after serial number 304 Move the 3200 pg number 1733 and secondary boom toggle Z 34 22N after serial switch in the UP direction number 2226 item YY and check the pressure OR repair or replace 2 34 22 after serial cylinder s or cylinde
210. controller in the RIGHT direction Check voltage at TB37 Repair or replace the steer microswitch on the the drive controller OR consult Genie Industries Service Department 20V or more Press down the foot switch and press the steer rocker switch in the RIGHT direction Check voltage on TB19 Repair open in grn wht 19 wire circuit with diode from TB37 to TB19 OR replace the diode 20V or more Press down the foot switch and press the steer rocker switch in the RIGHT direction Check voltage on the blu blk 37 wire at the steer right directional valve coil item CJ Repair open in blu blk 37 wire circuit from TB37 to the steer right directional valve coil OR repair open in brn ground wire circuit to the function manifold 20V or more 0 or infinite ohms Replace steer right directional valve coil Disconnect the blu blk 37 wire to the steer right directional valve coil Test the resistance of the valve coil See Repair Section 23 to 25 ohms Continued on the next page Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 5 Troubleshooting Flow Charts CHART 27 Conti Exchange the steer ontinued from the directional valve Replace defective previous page item CJ with turntable directional valve rotate directional valve item CX Test the steer left function function inoperative Install a 0 to 5000 PSI Check for mec
211. controls and pull both Emergency Stop buttons out to the ON position With the boom function speed controller turned to 9 press down the foot switch Hold the jib function toggle switch in the DOWN direction and check voltage on wht jib wire on jib down directional valve coil 20V or more Troubleshoot jib function toggle switch on ground controls OR replace diode on toggle switch OR repair open in grn 1 to sht jib wire circuit from toggle switch to jib down directional valve coil OR consult Genie Industries Service Department First Edition Third Printing 20V or more Repair open in grn blk 1 to wht jib wire circuit from TB44 to jib down directional valve coil OR repair open in ground wire circuit to valve coil Troubleshoot jib function toggle switches on ground and platform controls OR replace diodes on toggle switches OR repair open in grn blk 1 to wht jib wire circuit from toggle switches to jib down directional valve coil OR consult Genie Industries Service Department If voltage to jib down directional valve coil from ground toggle switch and platform toggle switch has been restored and jib up function is still inoperative continue trouble shooting from beginning of chart 5 92 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 5 Troubleshooting Flow Charts CHART 23 0 or infinite ohms Disconnect the wires f
212. ct and plug the extension 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 9 Remove the retaining fastener from the extension cylinder barrel end pivot pin Use a soft metal drift to remove the pin Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 7 25 Section 7 Repair Procedures First Edition Third Printing PRIMARY BOOM COMPONENTS 10 Carefully pull out and properly support the extension cylinder from the primary extension boomtube AWARNING Crushing hazard The cylinder will fall if it is not properly supported when it is pulled out of the extension boom tube To make installation of the extension cylinder easier be sure that the cylinder rod is extended approximately 3 to 4 feet 0 9 to 1 2 m 4 5 Platform Leveling Master Cylinder The master cylinder acts as a pump for the slave cylinder It is part of the closed circuit hydraulic loop that keeps the platform level through the entire range of primary boom motion The master cylinder is located inside the upper mid pivot at the pivot end of the primary boom How to Remove the Platform Leveling Master Cylinder AWARNING P dily injury hazard This procedure requires specific repair skills lifting equipment and a suitable
213. ction Check voltage at TB6 15V Continued on the next page Repair open in the wht red 6 wire circuit from TB6 to the boom function proportional valve coil OR repair open in the brn ground wire circuit from the boom function proportional valve coil to ground Repair open in the blk red wire to the wht red wire to TB6 5 34 Genie 7 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 5 Troubleshooting Flow Charts CHART 9 Press down the foot Repair open in the wire switch and move the circuit through the boom primary boom toggle function toggle switches switch in the UP to the red wire on the direction Check for boom function speed voltage at the red wire controller on the boom function speed controller Continued from the previous page Press down the foot Repair open in the switch and move the ground wire circuit from primary boom toggle the boom function speed switch in the uP controller to ground OR direction Check voltage replace the boom at the blk red wire on the function speed boom function speed controller controller Repair open in the blk red to wht red wire from the boom function speed controller to TB6 Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 5 35 Section 5 Troubleshooting Flow Charts EEEE CHART 9 Continued from page 34 Z 34 22 before serial number 153 and Z34 22N before serial n
214. ctions very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 5 Remove the drain plug from the hydraulic tank and drain the oil into a suitable container HYDRAULIC TANK 6 Tag disconnect and plug the hydraulic hoses from the hydraulic tank filter Cap the fittings on the filter 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 Bodily injury hazard Beware of hot ACAUTION oil Contact with hot oil may cause severe burns 7 Remove the hydraulic tank mounting fasteners 8 Remove the hydraulic tank from the machine 9 Remove the tank lid retaining fasteners Remove the lid from the tank Component damage hazard Do CAUTION not overtighten the hydraulic tank mounting fasteners Torque the hydraulic tank mounting fasteners to 5 ft lbs 6 8 Nm Torque specification 1 4 20 fasteners 5 ft lbs 6 8 Nm Hydraulic Oil Specifications Hydraulic oil type Dexron equivalent Z 34 22 after serial number 808 and Z 34 22N after serial number 1115 Hydraulic tank capacity 4 gallons Bodily injury hazard Beware of hot 15 1 liters ACAUTION oil Contact with hot oil may cause rmm nE ydraulic system gallon including tank 22 7 liters Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 7 57 Section 7
215. cylinder or cylinder switch to either side and counterbalance valve move the primary boom OR function manifold toggle switch in the could have an internal down direction and defect Consult Genie check the pressure Industries Service Department 3200 PSI Check for mechanical restrictions keeping the primary boom down function from operating OR repair cylinder or cylinder counterbalance valve OR consult Genie Industries Service Department Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 5 41 Section 5 Troubleshooting Flow Charts First Edition Third Printing Chart 11 Secondary Boom Up Function inoperative Be sure key switch is in the appropriate position Be sure the Emergency Stop buttons are pulled out to the on position Be sure the battery packs are properly connected and fully charged Turn key switch to ground controls and pull both Emergency Stop buttons out to the ON position 2 34 22 before serial number 153 and Z34 22N before serial number 304 Move the secondary boom toggle switch 7511 in the UP direction and check voltage on the wht red 6 wire at the boom function proportional valve coil item AU or BU or CH Z 34 22 from serial number 153 to 1733 and Z 34 22N from serial number 304 to 2226 Hold the function enable toggle switch to either side and move the secondary boom toggle switch TS11 in the UP direction and check voltage on the wht red 6 wire at the boom functi
216. d Printing Ground Control Panel Wiring Diagram 7 34 22 from serial number 1734 to 1999 7 34 22 from serial number 2227 to 2750 A B C BRN A3 A2 BRN OPTION NUMBERS 1 PLATFORM LEVEL CUTOUT 2 FLASHING BEACON 3 DESCENT ALARM 1 HM TS51 NO NO olo TS57 TS63 e ORG TS59 TS61 o 1555 ORG TS58 TS60 TS62 ORG O DESCENT ALARM WIRING OPTION CONTROL RELAY 1 0 SPARE WIRE LIST CR1 SECONDARY 48V POWER BLK 1 CR2 PRIMARY 48V POWER BLK WHT 1 AUXILIARY PUMP BLK RED 1 CR4 HORN BLU WHT 1 CR5 BRAKE RELEASE BLU RED 1 CR10A PLATFORM LEVEL CUTOUT CE OPTION ORG 1 CR10B PLATFORM LEVEL CUTOUT CE OPTION ORG BLK 1 GRN WHT 1 PLATFORM LEVEL CUTOUT CE OPTION Genie Z 34 22 amp Genie Z 34 22N Part No 36540 BRN CB2 BLK OPTION 2 52 GROUND BR
217. d Z 34 22N from serial number 304 to 2226 Hold the function enable toggle switch to either side and move the platform rotate toggle Switch TS15 in the RIGHT direction and check the voltage on the wht red 6 wire at the boom function proportional valve coil item AU or BU Z 34 22 after serial number 1733 and Z 34 22N after serial number 2226 Hold the function enable toggle switch to either side and move the platform rotate toggle switch TS57 in the RIGHT direction and check the voltage on the wht red 6 wire at the boom function proportional valve coil item CH 24N Continued on page 86 First Edition Third Printing 2 34 22 before serial number 153 and Z34 22N before serial number 304 Movethe 24V platform rotate toggle Switch in the RIGHT direction and check the voltage at TB6 2 34 22 after serial number 152 and Z34 22N after serial number 303 Hold the function enable toggle Switch to either side and move the platfrom rotate toggle switch in the RIGHT direction and check the voltage at TB6 Repair open in wht red 6 wire circuit from TB6 to boom function proportional valve coil OR repair open in brn ground wire circuit to boom function proportional valve coil ov Turn key switch to Repair open in wht red platform controls and wire circuit from TP6 to pull both Emergency to TB6 Stop buttons out to the ON position With the boom function speed controller turned to 9
218. d control and pull Crushing hazard Keep hands out the Emergency Stop button to the AWARNING away 5 the Raa all position moving parts when lowering the 2 Extend the primary boom approximately secondary boom inches 25 om The lift cylinder safety chock is 3 Measure each wear pad Replace the wear pad available from Genie Industries if itis less than 0 41 inches 1 cm thick If the Genie part number 36555 wear pad is more than 0 41 inches 1 cm thick see 4 2 How to Shim the Primary Boom in the Repair Section 4 Extend and retract the primary boom through the entire range of motion to check for tight spots that could cause binding or scraping Always maintain squareness between the primary boom outer and inner tubes 4 28 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 4 Scheduled Maintenance Procedures 2 Check to ensure that each turntable bearing bolt is torqued in specified order to 190 ft lbs 258 Nm 9 4 6 7 O ge ET b p 04 149 945 Te aA O 8 5 X O Vw 12 5 10 Bolt torque sequence Z 34 22 before serial number 1735 and Z 34 22N before serial number 2240 9 1 4 7 FU O N ol 20 5 120 N P4 wan 6 5 8 10 Bolt torque sequence Z 34 22 after serial number 1734 and Z 34 22N after serial number 2239 3 Raise boom and remove the safety chock Lower the boom to the
219. de of PR3 Z 34 22N after 303 Z 34 22 from serial Repair or replace the number 153 to 1733 positive cable from the and Z 34 22N from lift pump motor to PR2 serial number 304 to 2226 Hold the function enable switch to either side and move the primary boom extend retract toggle switch in the RETRACT direction and check voltage at the positive cable on the output side of PR3 Z 34 22 after serial number 1733 and Z 34 22N after 2226 Hold the function enable switch to either side and move the primary boom extend retract toggle switch in the RETRACT direction and check voltage at the positive cable on the output side of PR2 Z 34 22 before serial Z 34 22 before serial number 1734 and number 1734 and Z 34 22N before serial Z 34 22N before serial number 2227 Check number 2227 Replace voltage at the positive the 100A fuse F2 OR cable on the input side repair open in the of PR3 positive cable from the Z 34 22 after serial battery packs to the number 1733 and 100A fuse F2 to PR3 Z 34 22N after 2226 OR consult Genie Check voltage at the Industries Service positive cable on the Department input side of PR2 Z 34 22 after serial number 1733 and Z 34 22N after 2226 Replace the 100A fuse F2 OR repair open in the positive cable from the battery packs to the Continued on the next 100A fuse F2 to PR2 page OR consult Genie Industries Service Department Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 5 11 Section 5 Troubleshoot
220. dition Third Printing CHART 25 function Continued from the Exchange the steer operates_ Replace defective directional valve item ire previous page CJ with the turntable directional valve rotate directional valve item CX Test the steer left function function inoperative Install a 0 to 5000 PSI Check for mechanical 0 to 345 bar pressure restrictions keeping the gauge at the quick steer right function from disconnect coupling on operating OR the 0 045 the function manifold orifice item CN may be Press down the foot plugged OR repair or switch and press the replace the steer steer rocker switch in cylinder OR consult the LEFT direction and Genie Industries Service check the pressure Department less than 3200 psi Repair or replace the steer cylinder OR the function manifold may have an internal defect Consult Genie Industries Service Department 5 96 Genie 2 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 5 Troubleshooting Flow Charts Steer Right Function Inoperative Z 34 22 before serial number 1734 and Z 34 22N before serial number 2227 Be sure key switch is in the appropriate position Be sure the Emergency Stop buttons are pulled up to the on position Be sure the battery packs are properly connected and fully charged Be sure all other functions operate normally Turn key switch to p
221. down foot switch and check voltage at blk 12 wire LS3 20V or more Press down foot switch and check voltage at red 16 wire on LS3 20V or more Press down foot switch and check voltage at 16 20V or more Continued on the next page Repair open in the wire circuit from the platform Emergency Stop button P2 to foot switch Replace foot switch contacts OR replace the foot switch Repair open in the blu wht 3 wire circuit from foot switch to TB12 Repair open in the blk 12 wire circuit from 12 to LS3 Replace LS3 Repair open in red 16 wire from LS3 to TB16 First Edition Third Printing 5 28 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 5 Troubleshooting Flow Charts CHART 7 Press down foot switch Z 34 22 before serial Continued from the and check voltage at number 153 and previous page terminal on the drive Z34 22N before serial controller number 304 Repair open in the org red 3 wire circuit from TB16 to terminal on the drive controller Z 34 22 after serial number 152 and Z34 22N after serial number 303 Repair open in r wire circuit from TB16 to 5 OR repair or replace CR5 OR repair open in the brn ground wire circuit from CR5 to ground Turn the boom function Repair open in the speed controller to 9 power supply circuit press down foot switch from each
222. down the foot switch and move the drive controller in either direction and check voltage at 41 24V Press down the foot switch and move the drive controller in either direction and check voltage at terminal 30 on CR5 24N Press down the foot switch and move the drive controller in either direction and check voltage at terminal 487 on CR5 24N Continued on the next page yes Refer to the fault code chart at the beginning of this section to determine the cause of the fault Press down the foot switch and move the drive controller in either direction and check the voltage at TP41 24N Repair open in org blk wire from TB41 to TP41 Repair open in org blk 41 wire from TB41 to terminal 30 on CR5 Do not press down the foot switch Check voltage at the red blk wire on pin 20 of the motor controller harness connector 48V Press down the foot Switch and check voltage at the red blk wire on pin 20 of the motor controller harness connector 24N Replace 5 Chart 30 See Chart 38 Drive Enable System Inoperative Repair open in org red wire circuit from TB42 to terminal 85 on CR5 OR repair open in red blk wire from pin 20 to terminal 86 on CR5 OR replace CR5 Replace the motor controller Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 5 117 Section 5 Troubleshooting Flow Charts
223. down the foot switch and slowly move the drive controller from neutral to full stroke in the FORWARD direction and check voltage at terminal A on the drive controller Voltage should ramp up from OV to 5V 2 34 22 after serial number 152 and Z34 22N after serial number 303 Press down the foot switch and slowly move the drive controller from neutral to full stroke in the FORWARD direction and check voltage at terminal D on the drive controller Voltage should ramp up from OV to 5V bad Adjust the drive controller OR refer to Chart 33 OR repair or replace the drive controller OR consult Genie Industries Service Department First Edition Third Printing good good Repair open in red wht wire circuit from TB3 to terminal 3 on the motor controller Z 34 22 before serial number 153 and Z34 22N before serial number 304 Repair open in red wht wire circuit from terminal A at the drive controller to TB3 to 3 terminal on the motor controller 2 34 22 after serial number 152 and Z34 22N after serial number 303 Repair open in red wht wire circuit from terminal D at the drive controller to TB3 to 3 terminal on the motor controller 5 104 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 5 Troubleshooting Flow Charts Continued from the previous page Disconnect wht wire on the forward reverse contactor PR2 Connect a vol
224. e Replace the motor controller 5 116 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 5 Troubleshooting Flow Charts Brake Release Function Inoperative Z 34 22 after serial number 1733 and Z 34 22N after serial number 2226 Be sure all other functions operate normally Troubleshooting brake release faults may also be accomplished by using the hand held pendant motor controller programmer Genie part number 56303 Be sure to check the motor controller status indicator light on the ground control box or on the motor controller If the motor controller status indicator light is flashing a fault code refer to the fault code chart at the beginning of this section Be sure the battery packs are properly connected and fully charged Be sure the circuit breakers and fuses are not tripped or blown Be sure the unit is in the fully stowed position with the boom located between the non steer end tires Turn key switch to platform controls and pull both Emergency Stop buttons out to the ON position Press down the foot switch and check the status indicator light on the motor controller to see if there is a fault Is there a fault no Block the steer wheels and raise the machine so drive tires are off the ground With key switch turned to platform controls and both Emergency Stop buttons pulled out to the ON position press
225. e Begin timing when your reference point on the machine crosses the start line 18 Continue at full speed and note the time when the reference point crosses the finish line 19 Adjust the drive lo range trimpot on the circuit board to achieve a 40 second drive speed time Turn the lo range trimpot clockwise to decrease the time or counterclockwise to increase the time PLATFORM CONTROLS 20 Lower the primary boom to the stowed position 21 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 22 Continue at full speed and note the time when the reference point crosses the finish line 23 Adjust max out trimpot on the drive circuit board to achieve the specified drive speed time refer to table below Turn the max out trimpot clockwise to decrease the time or counterclockwise to increase the time Drive controller specifications Brake board Threshold 0 16 amps when pump motor turns Max out 0 91 amps when pump motor turns orr Drive board Threshold 0 8 to 0 9V DC when amp output is 0 28 to 0 3 amps Max out 5 to 5 2V DC with boom stowed and joystick in full forward position Lo range 2 4 to 2 7V DC with boom raised and joystick in full forward position Drive speeds maximum Z 34 22 stowed position 49 1 drive hubs 3 1 mph 5 km h 40 ft 9 1 12 2 m 9 1 sec 35 1 drive hubs 4 mph 6
226. e release relay CR5 defective Main contactor PR1 contacts stuck closed 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 See Chart 29A See Chart 29A Replace main contactor PR1 or brake release relay CR5 OR replace the motor controller See Chart 29B Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 5 Troubleshooting Flow Charts FAULT CODE CHART Z 34 22 AFTER SERIAL NUMBER 1733 AND Z 34 22N AFTER SERIAL NUMBER 2226 Fault Code Programmer Condition Possible Causes Diagnostic Display PRECHARGE FAULT MISSING CONTACTOR MAIN CONT DNC LOW BATTERY VOLTAGE Machine will not drive Controller fault indicator light on at the platform controls Machine will not drive Controller fault indicator light on at the platform controls Machine will not drive Controller fault indicator light on at the platform controls Machine will not drive Controller fault indicator light on at the platform controls External short between B terminal on motor controller and ground OR motor controller is defective Motor controller does not detect the main contactor PR1 or brake release relay CR5 Main contactor PR1 or brake release relay CR5 did not close OR open in org red wire to PR1 and or CR5 OR main contactor and or brake release relay is def
227. e 65 Turn key switch to ground controls and pull both Emergency Stop buttons out to the ON position 2 34 22 before serial number 153 and Z34 22N before serial number 304 Move the turntable rotate toggle switch in the RIGHT direction and check voltage on the wht 5 wire on the turntable rotate directional valve coil item AK 2 34 22 from serial number 153 to 1733 and Z 34 22N from serial number 304 to 2226 Hold the function enable toggle switch to either side and move the turntable rotate toggle switch in the RIGHT direction and check voltage on the wht 5 wire on the turntable rotate directional valve coil item AK or Z 34 22 after serial number 1733 and Z 34 22N after serial number 2226 Hold the function enable toggle switch to either side and move the turntable rotate toggle switch in the RIGHT direction and check voltage on the wht 5 wire on the turntable rotate directional valve coil item CX 24V Continued on the next page Z 34 22 before serial number 153 and Z34 22N before serial number 304 Move the turntable rotate toggle switch in the RIGHT direction and check voltage at TB5 2 34 22 after serial number 152 and Z34 22N after serial number 303 Hold the function enable toggle switch to either side and move the turntable rotate toggle switch in the RIGHT direction and check voltage at TB5 Turn key switch to platform controls and pull both Emergency Stop buttons out to
228. e Se eei ete exe WHT FS BRN 2 21 22 52 BLU RED 3 WHT 5 BRN 5 ki 1 15 5 12 1 13 Shown with the boom BLU WHT 3 BLK 5 RED 5 DRIVE ENABLE LIMIT SWITCH TB16 ORG RED 3 n rotated past either non steer wheel ORG RED TRAVEL ALARM L t OPTION 8 RED WHT BRAKE RELEASE VALVE BRAKE RELEASE VALVE 51 PRESSURE SWITCH t STEER LEFT RELEASE RED WHT DRIVE ENABLE 48 WHT RED RED WHT 48 RED WHT 48 ES t RED WHT 7515 RED BLU 36 qj TB36 1837 E io a BLU 1 BLU BLK 1 BLU BLK 37 P t STEER RIGHT WHT BLK T HOUR METER amp DRIVE L STEER PLATFORM CONTROL BOX GROUND GRN WHT 19 GROUND WHT BLK FUNCTION MANIFOLD DP1 DRIVE CONTROLLER 1 He REV 4 ORG RED AUXILIARY PUMP Pi f CR3 AUXILIARY LIFT PUMP CONTACTOR RELAY GRN WHT CR20 LIFT PUMP TB27 85 RED 27 t gt AUXILIARY PUMP CONTACTOR RELAY CR3 86 s a RED 2 5 GRNMWHT PR2 LIFT PUMP 20 OR
229. e hammer and remove the pin soft metal drift to remove the pin 41 Remove the pin retainers from the lower 48 Remove the lower secondary boom from the mid pivot to lower secondary boom pivot pins machine ft metal dri in AWARNING Crushing hazard If the overhead 42 Remove the lower mid pivot from the machine crane is not properly attached the lower secondary boom may become unbalanced and fall when it is removed from the machine AWARNING Crushing hazard If the overhead crane is not properly attached the lower mid pivot may become unbalanced and fall when it is removed from the machine 43 Remove the drive speed limit switch mounted on the inside of the lower mid pivot Do not disconnect the wiring 44 Attach the strap from the crane to the control box side lower compression arm 45 Remove the pin retainer from the lower compression arm to turntable pivot pin Use a slide hammer and remove the pin Remove the arm from the machine Repeat for the engine side lower compression arm AWARNING Crushing hazard If the overhead crane is not properly attached the lower compression arms may become unbalanced and fall when it is removed from the machine 46 Attach the strap from the crane to the lower secondary boom 7 32 Genie 7 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 7 Repair Procedures 5 2 Secondary Boom Lift Cylinder The secondary boom lift cyli
230. e lug nuts then 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 9 if there is no movement 6 Remove the dust cap from the hub then remove the cotter pin from the castle nut Part No 36540 Genie Z 34 22 amp Genie Z 34 22N Section 4 Scheduled Maintenance Procedures First Edition Third Printing TABLE D PROCEDURES 7 Tighten the castle nut to 35 ft Ibs 47 Nm 8 Checkfor 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 proceed to step 9 to replace the wheel bearings with new ones When replacing a wheel bearing both the inner and outer bearings including the pressed in races must be replaced Result If there is no side to side or up and down movement grease the wheel bearings 9 Remove the castle nut Always replace the cotter pin with a new one when removing the castle nut 10 Pull the hub off of the spindle The washer and outer bearing should fall loose from the hub 11 Place the hub on a flat surface and gently pry the bearing seal out of the hub Remove the inner bearing 12 Pack both bearings with clean fresh grease 13 Place the large inner bearing into the rear of the hub 14 Install a new bearing gr
231. e magnet inside the tank and install the tank on the power unit 6 Fill the tank with hydraulic oil until the level is within the top 2 inches 5 cm of the hydraulic oil decal Do not overfill 7 Clean up any oil that may have spilled Z 34 22 after serial number 808 and Z 34 22N after serial number 1115 1 Close the hydraulic shut off valve located at the hydraulic tank Component damage hazard The CAUTION machine must not be operated with the hydraulic tank shut off valve in the position or component damage will occur If the tank valve is 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 See capacity specifications Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 4 33 Section 4 Scheduled Maintenance Procedures First Edition Third Printing TABLE D PROCEDURES 3 Disconnect and plug the hydraulic hose from the hydraulic tank shut off valve Bodily injury hazard Spraying AWARNING 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 Openthe valve on the hydraulic tank and drain the oil into a suitable container Bodily injury hazard Beware of ACAUTION hot oil Contact with hot oil may cause severe burns 5 Tag disconnect and plug the hydraulic hoses
232. e properly connected and fully charged Turn key switch to ground controls and pull both Emergency Stop buttons out to the on position Z 34 22 before serial number 153 and Z34 22N before serial number 304 Move the platform level toggle Switch TS14 in the UP direction and check the voltage on the wht red 6 wire at the boom function proportional valve coil item AU 27 34 22 from serial number 153 to 1733 and Z 34 22N from serial number 304 to 2226 Hold the function enable toggle switch to either side and move the platform level toggle switch TS14 in the UP direction and check the voltage on the wht red 6 wire at the boom function proportional valve coil item AU or BU Z 34 22 after serial number 1733 and Z 34 22N after serial number 2226 Hold the function enable toggle switch to either side and move the platform level toggle switch TS59 in the UP direction and check the voltage on the wht red 6 wire at the boom function proportional valve coil item CH 24N Continued on page 73 2 34 22 before serial number 153 and Z34 22N before serial number 304 Movethe 24V platform level toggle switch in the UP direction and check the voltage at TB6 2 34 22 after serial number 152 and 234 22 after serial number 303 Hold the function enable toggle switch to either side and move the platform level toggle switch in the UP direction and check the voltage at TB6 Turn key switch to platf
233. e the platform full left and right and inspect the bleed valves for leaks 12 Turn the key switch to the position and clean up any hydraulic oil that may have spilled Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 7 15 Section 7 Repair Procedures First Edition Third Printing Jib Boom Components 3 1 Jib Boom How to Remove the Jib Boom 1 Perform this procedure with the boom in the stowed position When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications Remove the platform See 2 1 How to Remove the Platform 2 Remove the platform mounting weldment and the platform rotator See 2 3 How to Remove the Platform Rotator 3 Tag disconnect and plug the jib boom lift cylinder hydraulic hoses Cap the fittings on the jib boom lift 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 4 Remove the cable cover from the side of the jib boom Remove the mounting fasteners from the jib boom platform rotate manifold Do not remove the hoses CAUTION Component damage hazard Hoses and cables can be damaged if they are twisted or kinked Attach a lif
234. ease seal into the hub by pressing it evenly into the hub until it is flush Always replace the bearing grease seal when removing the hub 15 Slide the hub onto the yoke spindle CAUTION Component damage hazard Do not apply excessive force or damage to the lip of the seal may occur 16 Place the outer bearing into the hub 17 Install the washer and castle nut 18 Tighten the castle nut to 35 ft Ibs 47 Nm to seat the bearings 19 Loosen the castle nut then tighten to 8 ft lbs 11 Nm 20 Install a new cotter pin Bend the cotter pin to lock it in place Always replace the cotter pin with a new one when removing the castle nut or when checking the torque of the castle nut 21 Install the dust cap 22 Install the tire and wheel assembly Torque the wheel lug nuts to 125 ft lbs 169 5 Nm Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 5 Troubleshooting Flow Charts Troubleshooting Flow Charts Observe and Obey Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine M 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 repair procedure with the machine in the following configuration Machine parked on a flat level surface Boom i
235. eck voltage at TB14 oV Turn key switch to platform controls and pull both Emergency Stop buttons out to the ON position With the boom function speed controller turned to 9 press down the foot switch and move the platform level toggle switch Z 34 22 before serial number 1734 and Z 34 22N before serial number 2227 TS5 Z 34 22 after serial number 1733 and Z 34 22N after serial number 2226 TS9 in the uP direction Check voltage at TB14 24V Repair org 3 wire to 14 24V Repair open in org 14 wire circuit from TB14 to platform level up directional valve coil OR repair open in brn ground wire circuit to the manifold Repair open in power supply wiring to platform level toggle switch Z 34 22 before serial number 1734 and Z 34 22N before serial number 2227 7514 Z 34 22 after serial number 1733 and Z 34 22N after serial number 2226 TS59 on ground controls OR Z 34 22 before serial number 1734 and Z 34 22N before serial number 2227 TS5 Z 34 22 after serial number 1733 and Z 34 22N after serial number 2226 TS9 on the platform controls Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 5 73 Section 5 Troubleshooting Flow Charts First Edition Third Printing CHART 18 Disconnect the org wire O or from the platform level infinite up directional valve coil ohms Test the resistance of the valve coil See Repair Section
236. ective Battery supply voltage to motor controller less than 32V Repair short between B terminal on motor controller and ground OR replace motor controller Note Short can be on any part of circuit connected to the B terminal on the motor controller See Chart 29C See Chart 29C Completely charge batteries OR check battery cable condition OR check for corrosion or loose connections at battery terminals and motor controller Part No 36540 Genie Z 34 22 amp Genie Z 34 22N Section 5 Troubleshooting Flow Charts First Edition Third Printing FAULT CODE CHART Z 34 22 AFTER SERIAL NUMBER 1733 AND Z 34 22N AFTER SERIAL NUMBER 2226 Fault Code Programmar Condition Possible Causes Diagnostic Display THERMAL CUTBACK Machine will not drive Controller fault indicator light on at the platform controls Machine will not drive Controller fault indicator light on at the platform controls Battery supply voltage to motor controller more than 55V OR machine is being operated with the battery charger plugged in Machine being operated outside of temperature range of 13 F to 185 F 25 C to 85 C OR machine being driven under excessive load OR motor controller is not being cooled sufficently Be sure the battery charger is disconnected OR check for loose battery cables or poor connections Operate machine within specified temperature limits OR check for debris around
237. ed on the next page 20V or more Press down the foot switch and check voltage at TB16 oV 20V or Press down the foot m re switch and check voltage at TB12 Repair open in blu wht 3 wire circuit from drive enable toggle switch to TB12 OR consult Genie Industries Service Department Repair open in power cable from battery packs to F1 OR ground cable to B terminal on the motor controller Z 34 22 before serial number 153 and Z34 22N before serial number 304 Repair open in org red wire circuit from TB16 to terminal on the drive controller 2 34 22 after serial number 152 and Z34 22N after serial number 303 Repair open in org red wire circuit from TB16 to CR5 OR repair open in ground wire circuit from CR5 to ground OR repair open in blu wht wire circuit from center pole at TS9 to CR5 OR repair open in wire circuit from CR5 to terminal on the drive controller OR replace CR5 Repair open in wire circuit from TB12 to LS3 OR repair open in wire circuit from TB16 to LS3 OR replace LS3 5 100 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 5 Troubleshooting Flow Charts Check voltage on output side of 500A fuse F1 Continued from the previous page Check voltage on the positive cable at input side of PR1 Press down the foot switch and move the drive controller in the FORWARD direction and
238. eeeeeneenn nennen 7 23 4 4 Extension Cylinder 7 25 4 5 Platform Leveling Master 7 26 Secondary Boom Components 5 1 Secondary BOOM idet T teer Lat et dene el ES Pate ertet 7 29 5 2 Secondary Boom Lift Cylinder 7 33 36540 Genie Z 34 22 amp Genie Z 34 22N XVii First Edition Third Printing TABLE OF CONTENTS Section Seven Repair Procedures continued Ground Controls 6 1 Contool Relays oid ae e tir pe Stc Eo e e rut 7 34 6 2 Toggle Switches See 1 3 Toggle 22 2 09 7 36 6 3 Wago Components 7 36 Hydraulic Pumps TA Auxiliary a heeren t teet ee Heg ean ee alk exce netted 7 37 7 2 Main Function Pump nne enn nnne 7 38 Manifolds 8 1 Function Manifold Components Z 34 22 before serial number 674 and Z 34 22N before serial number 935 7 40 82 Function Manifold Components Z 34 22 from serial number 674 to 1733 and Z 34 22N from serial number 935 to 2226 7 42 8 3 Function Manifold Components Z 34 22 after serial number 1733 and Z 34 22N after serial number 2226 7 44 8 4 Valve Adjustments Function
239. efore serial number 1734 and Z 34 22N before serial number 2227 Be sure key switch is in the appropriate position Be sure the Emergency Stop buttons are pulled out to the on position Be sure the battery packs are properly connected and fully charged Be sure all other functions operate normally Turn key switch to platform controls and pull both Emergency Stop buttons out to the ON position Press down the foot switch and press the steer rocker switch in the LEFT direction and check voltage on TB36 20V or more Press down the foot switch and press the steer rocker switch in the LEFT direction and check voltage on TB19 20V or more Press down the foot switch and press the 20V or steer rocker switch in more the LEFT direction and check voltage on blu 36 wire at the steer left directional valve coil item on the steer brake manifold ov Repair open in blu 36 wire circuit from TB36 to the steer left directional valve coil Press down the foot switch and press the steer rocker switch in the LEFT direction and check voltage at the drive contoller terminal with the blu 1 wire attached 20V or more Repair open in blu 1 wire circuit from drive controller to TB36 Repair open in the wire circuit with diode from TB36 to TB19 0 or infinite ohms Disconnect the wires from the steer left directional valve coil Test the resistance of the valve co
240. elief valve 1400 psi 97 bar AS Primary boom down 25 30 ft Ibs 34 41 Nm 20 Relief valve 1800 psi 124 bar Boom 25 30 ft lbs 34 41 Nm 21 Proportional solenoid valve AU System flow regulating circuit 10 12 ft lbs 14 16 Nm 22 Diagnostic fitting Testing Plug Torque Specifications Description Hex Size Torque Description Hex Size Torque SAE No 2 1 8 50 in Ibs 6 Nm SAE No 6 1 4 18 ft lbs 24 Nm SAE No 4 3 16 13 ft lbs 18 Nm SAE No 8 5 16 50 ft lbs 68 Nm 7 40 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 7 Repair Procedures MANIFOLDS N Q i lt lt AC 90 2 O f I ali Ws Ga ZS e QN 6 ep 99 On AS S 9 ep a Gp Ol G 925 Seo e A d D AQ c AD a Ce Sag SS AP lt 9 J x wt MX lt lt 25 AJ T EZI 2 AN S AL 9 Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 7 41 Section 7 Repair Procedures First Edition Third Printing _ CLER Lp M I1 MANIFOLDS 8 2 Function Manifold Components 7 34 22 from serial number 674 to 1733 and Z 34 22N from serial nu
241. emove the Auxiliary Pump 1 Tag disconnect and plug the hydraulic hoses from the pump Cap the fittings on the pump AWARNING ad injury hazard Spraying ydraulic 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 pump mounting bolts Carefully remove the pump Part No 36540 Genie Z 34 22 amp Genie Z 34 22N Section 7 Repair Procedures First Edition Third Printing HYDRAULIC PUMPS 7 2 Main Function Pump How to Test the Main Function Pump 1 Disconnect and plug the high pressure hydraulic hose from the main function pump Bodily injury hazard Spraying AWARNING 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 When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 2 Connect a 0 to 5000 psi 0 to 350 bar pressure gauge to the high pressure port on the pump 3 Turn the key switch to ground control and pull out the Emergency Stop button to the position at both the ground and platform controls 4 Z 34 22 before serial number 153 and Z 34 22N before serial number 304 Move any
242. en removing the 1 Loosen the wheel lug nuts Do not clevis pin remove them 6 Remove the retaining fasteners from the upper and lower yoke pivot pins Do not remove the pins 7 Support and secure the yoke hub assembly to a lifting jack 8 Place a rod through the yoke pivot pins and twist to remove the pins Crushing hazard The yoke hub ACAUTION assembly may become unbalanced and fall when the a axle yoke pivot pins are removed if it is b retainingfastener not properly supported and 6 Kingpin secured to the lifting jack d yoke e hub TT f clevis and cotter pin Torque specifications g steeringcylinder h tierod Lug nuts dry 125 ft lbs 169 5 Nm Lug nut torque lubricated 94 ft lbs 127 Nm 2 Block the non steering wheels Center a lifting jack under the steering axle 3 Raise the machine approximately 6 inches 15 cm and place blocks under the drive chassis for support Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 7 59 Section 7 Repair Procedures First Edition Third Printing STEERING AXLE COMPONENTS How to Remove the Hub and Bearings 1 Loosen the wheel lug nuts Do not remove them 2 Block the non steering wheels and place a lifting jack under the steering axle 3 Raise the machine approximately 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 Remove the dust cap cotter pin
243. ent damage may also result if problems are not discovered and repaired in a timely fashion 1 Check the tire surface and sidewalls for cuts cracks and unusual wear 2 Check each wheel for damage bends and cracked welds 3 Check each lug nut for proper torque Tires and wheels 169 5 Nm 129 Nm 125 ft lbs 95 ft lbs Lug nut torque dry Lug nut torque lubricated B 4 Confirm the Proper Brake Configuration Proper brake configuration is essential to safe operation and good machine performance 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 Foo brake disengage position arf arf _ brake engage position Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 4 Scheduled Maintenance Procedures B 5 Check the Oil Level in the Drive Hubs 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 one of the plugs is located on top and the other is at 90 degrees 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 3 If necessary remove the top plug and
244. er 5 Secure the upper secondary boom to the pivot the master cylinder out of the machine end of the primary boom with a strap this will prevent the upper secondary boom from falling when the master cylinder barrel end pivot pin is removed from the cylinder 6 Tag disconnect and plug the master cylinder hydraulic hoses Cap the fittings on the master 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 7 Attach a lifting strap to the lug on the rod end of the master cylinder Secure the strap to the primary boom use this strap to lower the master cylinder out of the upper mid pivot 8 Remove the pin retaining fastener from the master cylinder rod end pivot pin Use a soft metal drift to remove the pin 9 Remove the pin retaining fastener from the master cylinder barrel end pivot pin Do not remove the pin from the upper mid pivot Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 7 27 Section 7 Repair Procedures First Edition Third Printing Secondary Boom Components Secondary Boom a b f 9 upper mid pivot upper compression arm compression link lower mid pivot lower secondary boom turntable pivot lower compression arm upper secondary boom Genie Z 34 22 am
245. er 152 and Z34 22N after serial number 303 Hold the function enable toggle switch to either side and move the platfrom rotate toggle switch in the LEFT direction and check the voltage at TB6 Turn key switch to platform controls and pull both Emergency Stop buttons out to the ON position With the boom function speed controller turned to 9 press down the foot switch and move the platform rotate toggle switch Z 34 22 before serial number 1734 and Z 34 22N before serial number 2227 TS6 2 34 22 after serial number 1733 and Z 34 22N after serial number 2226 TS7 in the LEFT direction Check voltage at TP6 Continued on the next page Repair open in wht red 6 wire circuit from TB6 to boom function proportional valve coil OR repair open in brn ground wire circuit to boom function proportional valve coil Repair open in wht red wire circuit from TP6 to to TB6 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 5 Troubleshooting Flow Charts CHART 20 Press down the foot Repair open in grn wht switch and move the wire circuit through platform level toggle boom function toggle switch in the LEFT switches to the red wire direction Check the on the boom function voltage at the red wire speed controller on the boom function speed controller Continued from the previous page Press down the foot Repair open in ground switch and m
246. er 4261 to 5619 A B C D E F G H J K L M ak LABEL DESCRIPTION BEDS eT RED C23 1 1 OPTION 2 134A KEYSWITCH POWER P1 EMERGENCY STOP BUTTON REDAWHT TILT WHT 2 134 RED A6 RED KSI KEYSWITCH POWER BRN CB2 BLK OPTION 2 52 BRN CH BRN CR4 GROUND KEYSWITCH BLUREDA dE BRN 5 BRN 2 52 BRN MH BRN SP GROUND TS51 AUXILIARY SWITCH a2 BEN WHT 6 WHT 8 50 182 154 JUNCTION EOM 2 BAN TS55 FUNCTION ENABLE SWITCH 1 BLK 7 BLK 6 49 LS1 LS2 JUNCTION 2 _ M wuveuesP 5 48 RED WHT M
247. er 4799 and 2 34 22 after serial number 5619 Ground Control Terminal Strip Wiring Diagram Z 34 22 after serial number 4799 and Z 34 22N after serial number 5619 Platform Control Box Wiring Diagram Z 34 22 before serial number 1734 and Z 34 22N before 2227 Platform Control Box Wiring Diagram Z 34 22 from serial number 1734 to 1834 and Z 34 22N from serial number 2227 to 2448 Platform Control Box Wiring Diagram Z 34 22 from serial number 1835 to 2060 and Z 34 22N from serial number 2449 to 2870 Platform Control Box Wiring Diagram Z 34 22 from serial number 2061 to 3577 and Z 34 22N from serial number 2871 to 4260 Platform Control Box Wiring Diagram Z 34 22 after serial number 3577 and Z 34 22N after serial number 4260 TABLE OF CONTENTS Part No 36540 Genie Z 34 22 amp Genie Z 34 22N First Edition Third Printing TABLE CONTENTS Section Six Schematics continued Hydraulic Schematic Z 34 22 before serial number 674 and Z 34 22N before serial 935 6 41 Hydraulic Schematic Z 34 22 from serial number 674 to 1733 and Z 34 22N from serial number 935 to 2226 6 42 Hydraulic Sc
248. er center terminal at TS15 direction Check voltage to TB12 at the center terminal at TS15 Press down the foot Repair open blu wht switch and move the 12 wire circuit from drive controller in either terminal 2 at the motor direction Check voltage controller to TB12 at terminal 2 at the motor controller OV Replace the motor controller OR contact Genie Industries Service Department Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 5 111 Section 5 Troubleshooting Flow Charts First Edition Third Printing Chart 29A Motor Controller Fault Code 21 Throttle Fault Z 34 22 after serial number 1733 and Z 34 22N after serial number 2226 Troubleshooting drive function faults may also be accomplished by using the hand held pendant motor controller programmer Genie part number 56303 Be sure to check the motor controller status indicator light on the ground control box or on the motor controller If the motor controller status indicator light is flashing a fault code refer to the fault code chart at the beginning of this section Be sure the circuit breakers and fuses are not tripped or blown Be sure the battery packs are properly connected and fully charged Be sure the machine is not in the free wheel configuration Be sure the unit is in the fully stowed position with the boom located between the non steer end tires Turn key switch to the OFF position and disconnect
249. er secondary boom Pull all the cables and hoses to the back of the turntable 35 Remove the retaining fasteners from the secondary boom lift cylinder barrel end pivot pins 36 Attach the strap from the crane to the lug on the rod end of the secondary boom lift cylinder 37 Tag disconnect and plug the hydraulic hoses from the secondary boom lift cylinder Cap the fittings on the cylinder Bodily injury hazard Spraying AWARNING 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 38 Use a slide hammer to remove the barrel end pins access the pins from the access holes in the bulkheads one on each side Then remove the cylinder from the machine Crushing hazard If the overhead AWARNING crane is not properly attached the secondary boom lift cylinder may become unbalanced and fall when itis removed from the machine 39 Attach the strap from the crane to the lower mid pivot Part No 36540 Genie Z 34 22 amp Genie Z 34 22N Section 7 Repair Procedures First Edition Third Printing M M ri SECONDARY BOOM COMPONENTS 40 Remove the pin retainers from the lower 47 Remove the pin retainer from the lower mid pivot to lower compression arm pivot pins secondary boom to turntable pivot pin Use a Use a slid
250. er serial number 1733 and Z 34 22N after serial number 2226 Remove the machine from service immediately Be sure the wiring to the limit switches is intact and shows no signs of damage or corrosion Be sure the primary boom drive limit switch is being activated by the cam on the boom when the primary boom is raised Be sure the secondary boom drive limit switch is being activated by the secondary boom compression arm when the secondary boom is raised Turn key switch to ground controls and pull yes both Emergency Stop buttons out to the ON position Check the status indicator light on the motor controller to see if there is a fault Is there a fault no With the boom in the lowered position check voltage at pin 3 on the motor controller harness connector 24V Raise the primary boom approximately 10 feet 24V 3m and check voltage at pin 3 on the motor controller harness connector Lower the primary boom to the lowered position 24V and raise the secondary boom approximately 10 feet 3m Check voltage at pin 3 on the motor controller harness connector oV Lower the secondary boom to the lowered position and extend the primary boom approximately 12 inches 30 cm Check voltage at pin 3 on the motor controller harness connector 24V Replace the motor controller OR consult Genie Industries Service Department Refer to the fault code chart at the
251. erator s Manual Be sure that all necessary tools and test equipment are available and ready for use Schematics About This Section There are two groups of schematics in this section AWARNING Electrocution burn hazard Contact with electrically charged circuits may result in death or serious injury Remove all rings watches and other jewelry Hydraulic Schematics Bodily injury hazard Spraying AWARNING 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 General Repair Process Malfunction Identify Troubleshoot discovered symptoms problem still exists Return to _ _ Perform service problem repair solved Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 6 1 Section 6 Schematics First Edition Third Printing p Electrical Components Item Description Genie Part Manufacturer Manufacturer Qty Number Part Number Part Number AP1 2 Anderson connector 19436 Anderson 63325 1 2 BAT1 Battery 6V DC 350 44820 Allied Battery Co L 16GH 8 BOL Battery charge indicator 23868 2 Curtis
252. essure Continued from the previous page less than 1200 psi Replace brake release valve half stroke item G OR replace brake proportional valve OR consult Genie Industries Service Department Install a 0 to 3000 psi 0 1655 than Replace pressure switch to 207 bar pressure 1200 psi OR consult Genie gauge at the quick Industries Service disconnect coupling on Department the function manifold Press down the foot switch and move the drive controller in the FORWARD direction and check pressure 1200 psi Check for mechanical restriction keeping drive function from operating OR consult Genie Industries Service Department Part No 36540 Genie 2 34 22 amp Genie Z 34 22N 5 109 Section 5 Troubleshooting Flow Charts First Edition Third Printing Chart 29 All Drive Functions Inoperative all Other Functions Operate Normally Z 34 22 after serial number 1733 and Z 34 22N after serial number 2226 Troubleshooting drive function faults may also be accomplished by using the hand held pendant motor controller programmer Genie part number 56303 Be sure to check the motor controller status indicator light on the ground control box or on the motor controller If the motor controller status indicator light is flashing a fault code refer to the fault code chart at the beginning of this section Be sure the circuit breakers and fuses are not tripped or blown
253. f Genie Industries PO Box 97030 Redmond WA 98073 9730 USA If you have any questions please contact Genie Industries Contact us http www genielift com e mail awp techpub terex com Genie Industries Copyright 1996 by Genie Industries First Edition First Printing June 1996 Second Printing February 2000 First Edition Third Printing August 2008 Genie and Z are registered trademarks of Genie Industries in the U S A and many other countries 6 Printed on recycled paper Printed in U S A li Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Safety Rules Danger Failure to obey the instructions and safety rules in this manual and the Genie Z 34 22 amp Genie Z 34 22N Operator s Manual will result in death or serious injury Many of the hazards identified in the operator s manual are also safety hazards when maintenance and repair procedures are performed Do Not Perform Maintenance Unless M You are trained and qualified to perform maintenance on this machine You read understand and obey manufacturer s instructions and safety rules employer s safety rules and worksite regulations applicable governmental regulations You have the appropriate tools lifting equipment and a suitable workshop Part No 36540 Genie Z 34 22 amp Genie Z 34 22N lii First Edition Third Printing SAFETY RULES Personal Safety
254. for tight spots that could cause scraping or binding Always maintain squareness between the outer and inner boom tubes a linkseparation point b lowerclip 1 Use a slotted screwdriver to pry down on the lower clip 2 Repeat step 1 for each link 3 To remove a single link open the lower clip and then use a screw driver to pry the link to the side Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 7 19 Section 7 Repair Procedures First Edition Third Printing PRIMARY BOOM COMPONENTS How to Remove the Primary 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 Perform this procedure with the boom in the stowed position When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Remove the platform See 2 1 How to Remove the Platform 2 Remove the platform rotator See 2 3 How to Remove the Platform Rotator 3 Remove the jib boom See 3 1 How to Remove the Jib Boom 4 Remove the jib boom bellcrank See 3 2 How to Remove the Jib Boom Bellcrank 5 Locate the 4 cables fr
255. from the hydraulic tank filter Cap the fittings on the filter 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 ACAUTION Bodily injury hazard Beware of hot oil Contact with hot oil may cause severe burns 6 Remove the hydraulic tank mounting fasteners 7 Remove the hydraulic tank from the machine 8 Remove the tank lid retaining fasteners and remove the lid and filter assembly from the tank 9 Remove the suction strainer from the tank and clean with a mild solvent 10 Rinse out the inside of the tank with a mild solvent 11 Install the lid and filter assembly onto the hydraulic tank 12 Install the suction strainer using a thread sealant on the threads 13 Install the hydraulic tank on the machine Install the hydraulic tank mounting fasteners and torque to 5 ft lbs 6 8 Nm Component damage hazard CAUTION hydraulic tank may become damaged if the tank mounting fasteners are over tightened 14 Install the hydraulic hoses 15 Fill the tank with hydraulic oil until the fluid is within the FULL and App marks on the hydraulic tank Do not overfill 16 Clean up any oil that may have spilled Properly discard the oil 17 Open the hydraulic tank shut off valve Component damage hazard Be CAUTION sure to open the hydraulic tank shut off va
256. fter serial number 1733 and Z 34 22N after serial number 2226 0 025 orifice item C could be plugged OR repair hydraulic rotation motor OR consult Genie Industried Service Department Replace platform rotate right directional valve coil Replace defective directional valve Repair hydraulic rotation motor OR platform rotate jib function manifold could have an internal defect Consult Genie Industries Service Department Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 5 87 Section 5 Troubleshooting Flow Charts First Edition Third Printing Chart 22 Jib Boom Up Function Inoperative Be sure key switch is in the appropriate position Be sure the Emergency Stop buttons are pulled out to the oN position Be sure the battery packs are properly connected and fully charged Turn key switch to ground controls and pull both Emergency Stop buttons out to the ON position 2 34 22 before serial number 153 and Z34 22N before serial number 304 Move the jib toggle switch 7516 in the UP direction and check the voltage on the wht red 6 wire at the boom function proportional valve coil item AU 27 34 22 from serial number 153 to 1733 and Z 34 22N from serial number 304 to 2226 Hold the function enable toggle switch to either side and move the jib toggle switch TS16 in the UP direction and check the voltage on the wht red 6 wire at the boom function proportional val
257. g Refer to the fault code chart in Section Five Limit switches There are two types of limit switches which are found in various locations on the machine drive speed limit switches and a drive enable limit Switch The function of a drive speed limit switch is to limit the raised machine drive speed to 0 6 miles per hour 1 km h when either the primary or secondary boom is raised more than 2 feet 0 6 m OR when the primary boom is extended more than 12 inches 30 cm The function of the drive enable limit switch is to limit the ability of the machine to drive when the boom is rotated outside the area between the non steer wheels Machine Controls The Z 34 22 and Z 34 22N machines are equipped with operational controls which are found in two locations the ground controls located opposite the hydraulic tank side of the machine and the platform controls located in the platform All lift and drive functions are available at the platform controls Only boom functions are available at the ground controls Moving a boom function toggle switch in the direction indicated on the control panel decal will determine which boom function will operate and its direction of travel The platform controls incorporates a rotary boom function speed controller which by varying the position of the controller controls the amount of voltage to the boom function proportional valve This controller determines the speed at which the function will
258. g the hand held pendant motor controller programmer Genie part number 56303 Be sure to check the motor controller status indicator light on the ground control box or on the motor controller If the motor controller status indicator light is flashing a fault code refer to the fault code chart at the beginning of this section Be sure the circuit breakers and fuses are not tripped or blown Be sure the battery packs are properly connected and fully charged Be sure the machine is not in the free wheel configuration Be sure the unit is in the fully stowed position with the boom located between the non steer end tires Disconnect the battery packs from the machine Visually inspect the contacts on PR1 Are the contacts stuck closed no Test the resistance between terminals M and B on the motor controller Note An ohmmeter capable of reading 1 ohm or less is needed for this test 1 ohm or less Remove the grn wire from PR1 Check continuity from the grn wire that was just removed from PR1 to the B terminal on the motor controller more than 500 kilohms Please begin troubleshooting from beginning of chart yes more than 1 ohm less than 500 kilohms Chart 29B Replace drive contactor PR1 contacts OR replace the drive contactor PR1 Test the resistance between terminals A1 and A2 on each drive motor Is the resistance 1 ohm or less on each drive
259. ginning of this section Be sure the circuit breakers and fuses are not tripped or blown Be sure the battery packs are properly connected and fully charged Be sure the machine is not in the free wheel configuration Be sure the unit is in the fully stowed position with the boom located between the non steer end tires Block the steer wheels and raise the machine 50 drive tires are off the ground Turn key switch to platform controls and pull both Emergency Stop buttons out to the ON position Press down the foot switch and check the voltage at pin 1 on the motor controller harness connector 48V Continued on the next page First Edition Third Printing Press down the foot 48V switch and check the voltage at TB42 ov Check voltage at TB3 ov 24V Check voltage at oV terminal 86 on CR2 24V Check the voltage at oV terminal 30 on CR1 48V Check the voltage at oV terminal 87 on CR1 48V Repair open in org red wire from terminal 87 on CR1 to TB42 Repair open in org red wire circuit with diode from TB42 to pin 1 on the motor controller harness connector OR replace the diode Repair open in red wht wire circuit from TB3 to platform Emergency Stop button P2 Repair open in red wht wire from TB3 to terminal 85 on CR2 Repair open in brn ground wire circuit from terminal 85 on CR2 to ground OR repair open in wire from terminal 87 on CR2 to terminal
260. gle switch TS59 in the DOWN direction and check the voltage on the wht red 6 wire at the boom function proportional valve coil item CH 24V Continued on page 78 2 34 22 before serial number 153 and 234 22 before serial number 304 Move the 24V platform level toggle switch in the DOWN direction and check the voltage at TB6 2 34 22 after serial number 152 and 234 22 after serial number 303 Hold the function enable toggle switch to either side and move the platform level toggle switch in the DOWN direction and check the voltage at TB6 ov Turn key switch to platform controls and pull both Emergency Stop buttons out to the ON position With the boom function speed controller turned to 9 press down the foot switch and move the platform level toggle switch 2 34 22 before serial number 1734 and Z 34 22N before serial number 2227 TS5 2 34 22 after serial number 1733 and Z 34 22N after serial number 2226 TS9 in the DOWN direction Check voltage at TP6 24V Continued on the next page Repair open in wht red 6 wire circuit from TB6 to the boom function proportional valve coil OR repair open in the ground wire circuit to the boom function proportional valve coil Repair open in wht red wire circuit from TP6 to to TB6 5 76 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 5 Troubleshooting Flow Charts
261. hanical 845 bar pressure restrictions keeping the gauge at the quick steer right function from disconnect coupling on operating OR the 0 450 the function manifold orifice item CN may be Press down the foot plugged OR repair or switch and press the replace the steer steer rocker switch in cylinder OR consult the RIGHT direction and Genie Industries Service check the pressure Department less than 3200 psi Repair or replace the steer cylinder OR the function manifold may have an internal defect Consult Genie Industries Service Department Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 5 99 Section 5 Troubleshooting Flow Charts First Edition Third Printing Chart 28 All Drive Functions inoperative All Other Functions Operate Normally Z 34 22 before serial number 1734 and Z 34 22N before serial number 2227 Be sure the unit is in the fully stowed position with the boom located between the drive tires Be sure the battery packs are properly connected and fully charged function Turn key switch to operates platform controls and pull both Emergency Stop buttons out to the ON position Press down the foot switch and hold the drive enable toggle switch TS9 to either side and move the drive controller in the FORWARD direction function inoperative Check voltage from B less than terminal on the motor 48V controller to input side of 500A fuse F1 48V or more Continu
262. he blu 10 wire on the secondary boom up directional valve coil item AE or BE or CT 2 34 22 after serial number 153 and Z 34 22N after serial number 304 Hold the function enable toggle switch to either side and move the secondary boom toggle switch in the up direction and check voltage on the blu 10 wire on the secondary boom up directional valve coil item AE or BE or CT 24V Continued on the next page First Edition Third Printing Z 34 22 before serial number 153 and Z34 22N before serial 24V number 304 Move the secondary boom toggle switch in the DOWN direction and check voltage at TB11 Z 34 22 after serial number 152 and Z34 22N after serial number 303 hold the function enable toggle switch to either side and move the secondary boom toggle switch in the DOWN direction and check voltage at TB11 Turn key switch to platform controls and pull both Emergency Stop buttons out to the ON position With the boom function speed controller turned to 9 press down the foot switch and move the secondary boom toggle switch in the DOWN direction and check voltage at TB10 24V Troubleshoot the secondary boom toggle switch OR replace diode on toggle switch OR repair open in blu 11 wire circuit from toggle switch to TB11 OR replace toggle switch Repair open in blu 11 wire circuit from TB11 to secondary boom down directional valve coil OR repair open in the ground wire circuit t
263. he machine from the ground controls whether 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 Push down the platform Emergency Stop button to the orr position 2 Turn the key switch to ground control and pull out the ground controls 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 TABLE B PROCEDURES B 9 Test the Platform Self leveling Automatic platform self leveling throughout the full cycle of boom raising and lowering is essential for safe machine operation The platform is maintained at level by the platform leveling slave cylinder which is controlled by the master cylinder located at the base of the primary boom A platform self leveling failure creates an unsafe working condition 1 Turn the key switch to ground control and pull out the Emergency Stop button to the oN position 2 Lowerthe boom to the stowed position 3 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 Part No 36540 Genie Z 34 22 amp Genie Z 34 22N Section 4 Scheduled Maintenance Procedures Fi
264. he wheels off the ground and then place jack stands under the drive chassis for support 4 Disengage the drive hubs by turning over the drive hub disconnect caps on each non steering wheel hub hoo brake disengage position org is arf No brake engage position 5 Manually rotate each non steering wheel Result Each non steering wheel should rotate with minimum effort Engage the drive hubs by turning over the drive hub disconnect caps Carefully remove the jack stands lower the machine and remove the jack Collision hazard Failure to AWARNING engage the drive hubs could cause death or serious injury and property damage 4 30 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 4 Scheduled Maintenance Procedures 4 Grease the Turntable Rotation Bearing and Worm Drive Gear Yearly application of lubrication to the turntable bearing and worm drive gear is essential to good machine performance and service life Continued use of an improperly greased gear will result in component damage 1 Locate the grease fitting mounted on the bulkhead next to the hydraulic power unit 2 Pump grease into the turntable rotation bearing Rotate the turntable in increments of 4 to 5 inches 10 to 13 cm at a time and repeat this step until the entire bearing has been greased 3 Locate the 3 grease fittings on the worm drive housing a grease fittings b grease
265. hematic Z 34 22 from serial number 1734 to 2005 and 2 34 22 from serial number 2227 to 2771 6 43 Hydraulic Schematic Z 34 22 from serial number 2006 to 2900 and Z 34 22N from serial number 27721035392 6 44 Hydraulic Schematic Z 34 22 after serial number 2900 and Z 34 22N after serial number 3532 6 45 Xvi Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing TABLE OF CONTENTS SectionSeven Repair Procedures E 7 1 Platform Controls del Controllers os fst i ate he a ed a EH tog ae 7 2 1 2 FOOUSWICN icai dee c e eer Rede 7 9 T 3 Toggle SwitChes vicina cree tee teret toe a ce Ee ease esu 7 10 Platform Components 2 1 Platform eei eB 7 11 2 2 Platform Leveling Slave Cylinder 04 222 00000 7 11 23 Platformhotator notice eth cn e dL aetna 7 13 Jib Boom Components 3 15 JID BOOITI aeterne Beesud iE EE 7 16 32 Boom Bell 0 aeea E po ONERE NERES 7 17 33 Jib Boom Lift Cylinder ae ienien inaen uesia iian daiak eiaei nne nnns 7 18 Primary Boom Components 4 1 Plastic Cable Track sesssssssesseseeeeeeeeeeennene nennen nnne nn nnne 7 19 4 2 gt Piman BOOMs niea iei oe EG d eas 7 19 4 3 Primary Boom Lift Cylinder sssessseseee
266. hine functions are performed by the hydraulic system The hydraulic system is powered by a single section gear pump When the pump is activated it supplies hydraulic fluid under pressure to the function manifold where the control valves are located To protect from over pressurization of the hydraulic system the pump is provided with a pressure relief valve set at 3200 psi 221 bar Activating a machine function is accomplished by actuating or moving a toggle switch and or control handle which sends voltage to the appropriate directional control valve The directional valve determines which direction the hydraulic fluid will travel The amount of hydraulic fluid volume is determined by the proportional valve input voltage from the boom function speed controller at the platform controls Each boom lift cylinder incorporates a counterbalance valve to prevent movement in the event of a hydraulic line failure Theory of Operation Electrical System Drive system All Z 34 22 and Z 34 22N machines utilize a DC drive motor on each non steer wheel The two motors are connected in series and are controlled by a solid state motor controller The motor controller regulates the amount of current applied to the drive motors based upon the position of the drive controller joystick which allows proportional drive speed control 2 34 22 machines before serial number 1734 and 2 34 22 machines before serial number 2227 use series wound D
267. hird Printing 7 34 22 from serial number 1734 to 1 205 Z 34 22N from serial number 2227 to 2 Electrical Schematic Section 6 Schematics z 2 mi te a 2 ka cc zz 8 zm Qt IS Z o E 4 m FUNCTION ENABLE io 8 1 1 eran P I ORG RED tB 48V POWER i RELAY CR2 RED WHT 8 1 8 6 2 5 ORG RED CR2 a EE m 48V POW RELAY CR1 1 1 RED WHT 8 E g WHT p RED BLK 28 lt RED BLK 1 Fo bog BRN
268. ht 25 30 ft lbs 34 41 Nm 5 Relief valve 1600 psi 110 bar CE Secondary boom down 25 30 ft lbs 34 41 Nm 6 Relief valve 1400 psi 96 5 bar GF ass Primary boom down 25 30 ft lbs 34 41 Nm Before serial number Z34 22 2901 and Z34 22N 3533 Relief valve 1600 psi 110 bar After serial number 234 22 2900 and Z 34 22N 3532 7 Relief valve 1800 psi 124 bar GG ius Primary boom extend 25 30 ft lbs 34 41 Nm Before serial number 234 22 2901 and Z34 22N 3533 Relief valve 2800 psi 193 bar From serial number Z34 22 2901 to 3215 and Z34 22N 3533 to 3766 8 Proportional solenoid valve GH System flow regulating circuit 10 12 ft Ibs 14 16 Nm 9 Check o Brake circuit 25 30 ft lbs 34 41 Nm 10 Solenoid valve 3 position 4 way CJ asse Steer left right 10 12 ft Ibs 14 16 Nm 11 position 4 way spool valve OK Primary boom extend retract 10 12 ft Ibs 14 16 Nm 12 Pressure switch GL ausis Brake circuit 13 Solenoid valve poppet CM Brake citcult enero ttt 25 30 ft lbs 34 41 Nm 14 Orifice 0 045 inch 1 02 mm CN Steer Brake circuit 15 Orifice 0 045 inch 1 5 mm
269. ial number 2227 Replace PR3 Z 34 22 after serial number 1733 and Z 34 22N after serial number 2226 Replace PR2 5 12 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 5 Troubleshooting Flow Charts CHART 2 Continued from the previous page 2 34 22 before serial number 153 and Z 34 22N before serial number 304 Move the primary boom extend retract toggle switch in the RETRACT direction and check voltage at terminal 2 on CR2 2 34 22 from serial number 153 to 1733 and Z 34 22N from serial number 304 to 2226 Hold the function enable switch to either side and move the primary boom extend retract toggle switch in the RETRACT direction and check voltage at terminal 5 on CR8 2 34 22 after serial number 1733 and 2 34 22N after 2226 Hold the function enable switch to either side and move the primary boom extend retract toggle switch in the RETRACT direction and check voltage at terminal 87 on CR20 Continued on the next page 2 34 22 before serial number 153 and Z 34 22N before serial number 304 Repair open in wire circuit from terminal 2 on CR2 to PR3 2 34 22 from serial number 153 to 1733 and Z 34 22N from serial number 304 to 2226 Repair open in wire circuit from terminal 5 on CR8 to PR3 2 34 22 after serial number 1733 and 2 34 22N after serial number 2226 Repair open in wire circuit from terminal 87 on CR
270. ide and move the platform rotate toggle switch in the LEFT direction and check voltage at TB17 Turn key switch to platform controls and 24V pull both Emergency Stop buttons out to the ON position With the boom function speed controller turned to 9 press down the foot switch and move the platform rotate toggle switch in the LEFT direction Check voltage at platform rotate left directional valve coil oV Repair open in power supply wiring to platform rotate toggle switch on ground controls or on the platform controls Repair open in org wire circuit from TB17 to platform rotate left directional valve coil OR repair open in brn ground wire circuit to the manifold Repair open in the ground wire circuit on the platform rotate left directional coil 5 82 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 5 Troubleshooting Flow Charts CHART 20 0 or infinite ohms Disconnect the org wire from the platform rotate left directional valve coil Replace platform rotate Test the resistance of left directional valve coil the valve coil See Repair Section Continued from the previous page Exchange the platform rotate left and jib boom up directional valves items D and A Activate the platform rotate LEFT function Replace defective directional valve function inoperative Install a 0 to 3000 psi Repair hydr
271. il See Repair Section 20 to 25 ohms Install a 0 to 3000 PSI 0 to 207 bar pressure gauge at the quick disconnect coupling on the boom function manifold Press down the foot switch and press the steer rocker switch in the LEFT direction and check the pressure 2800 psi less than 2800 psi Repair or replace steer cylinder OR the steer brake function manifold could have an internal defect OR consult Genie Industries Service Department Repair or replace the steer microswitch OR consult Genie Industries Service Department Replace steer left directional valve coil Check for mechanical restrictions keeping steer left function from moving OR the 0 085 Orifice item O is plugged OR repair or replace steer cylinder OR consult Genie Industries Service Department 5 94 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 5 Troubleshooting Flow Charts Steer Left Function Inoperative Z 34 22 after serial number 1733 and Z 34 22N after serial number 2226 Be sure key switch is in the appropriate position Be sure the Emergency Stop buttons are pulled out to the position Be sure the battery packs are properly connected and fully charged Be sure all other functions operate normally Turn key switch to platform controls and pull both Emergency Stop buttons out to the ON position Press down the foot swit
272. ing SSS el 11 2 Steer Cylinder When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Tag disconnect and plug the hydraulic hoses from the steer cylinder Cap the fittings on the cylinder AWARNING 2odil 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 cotter pins Remove the clevis pin from each end of the steer cylinder Always replace the cotter pin with a new one when removing the clevis pin 3 Remove the steer cylinder from the machine Section 7 Repair Procedures STEERING AXLE COMPONENTS 11 3 Tie Rod How to Remove the Tie Rod 1 Remove the cotter pins Remove the clevis pin from each end of the tie rod Always replace the cotter pin with a new one when removing the clevis pin 2 Remove the tie rod from the machine Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 7 61 Section 7 Repair Procedures First Edition Third Printing Non steer Axle Components 12 1 12 2 Drive Motor Drive Hub How to Remove a Drive Motor How to Remove a Drive Hub A drive motor can only be The drive motor must be removed removed from the inside of the in order to a
273. ing Flow Charts First Edition Third Printing CHART 2 2 34 22 before serial number 153 and Z 34 22N before serial number 304 Move the primary boom extend retract toggle switch in the RETRACT direction and check voltage on the grn wht wire at PR3 2 34 22 from serial number 153 to 1733 and Z 34 22N from serial number 304 to 2226 Hold the function enable switch to either side and move the primary boom extend retract toggle switch in the RETRACT direction and check voltage on the grn wht wire at PR3 2 34 22 after serial number 1733 and Z 34 22N after 2226 Hold the function enable switch to either side and move the primary boom extend retract toggle switch in the RETRACT direction and check voltage on the grn wht wire at PR2 Continued from the previous page Continued on the next page Z 34 22 before serial number 1734 and Z 34 22N before serial number 2227 Check for continuity in the brn ground wire circuit from to ground Z 34 22 after serial number 1733 and Z 34 22N after 2226 Check for continuity in the brn ground wire circuit from PR2 to 2 34 22 before serial number 1734 and Z 34 22N before serial number 2227 Repair open in the brn ground wire circuit from PR3 to ground 2 34 22 after serial number 1733 and Z 34 22N after serial number 2226 Repair open in the brn ground wire circuit from PR2 to ground Z 34 22 before serial number 1734 and Z 34 22N before ser
274. ion 1 4 ay 2 1 E I REDWHT 29 BRAKE RELEASE HALF STROKE ac 98 WHT BLK 1 a WHT BLK 31 He DRIVE FORWARD RELAY COIL 1 WHT 1 Pw WHT 30 Ye DRIVE REVERSE RELAY COIL io lf Y 8 EB BLU BLK 1 E BLU BLK 37 2 4 STEER RIGHT 720 i 6 BLU 1 BLU 36 7 Ye STEER LEFT 1 m we sI WHT REDSS BRAKE RELEASE PROPORTIONAL lt 3 B GRN WHT RED PRESSURE SWITCH WHT RED 1 Y H v y a N E 2 d AUXILIARY CONTROL RELAY COIL DRIVE ENABLE 53 H RED 27 a ev E AUXILIARY PUMP RELAY COIL 8 2 D 59 GRN WHT 3 n B GRN WHT4R2 gh s GRN IWHT LIFT PUMP RELAY COIL E WHT RED 3 WHT RED 6 BLU WHT 1 BLU WHT 48 i PROPORTIONAL FLOW amp CONTROL COIL x zer 2 ERE UP P JIB BOOM UP z 8 JIB BOOM 1 ci 2 JIB BOOM ia DOWN DOWN ene See ssa 1 Ik GRN 1 T Y GRN BLK 1 i 2 Els RIGHT B PLATFORM ROTATE 5 ES RIGHT GRN JIB He x PLATFORM ROTATE zi PLATFORM ROTATE LEFT LEFT 9 GRN BLK 3 GRN 3 i a i i ORGA sj G p PLATFORM LEVEL UP 1 n y i f e iS M NS PLATFORM LEVEL DOWN
275. ion Result No function should operate machine should stop B 7 Test the Emergency Stop Buttons Properly functioning Emergency Stop buttons are essential for safe machine operation An improperly operating Emergency Stop button will fail to shut off power and stop all machine functions resulting in a hazardous situation As a safety feature selecting and operating the ground controls will override the platform controls including the Emergency Stop button 1 Turn the key switch to ground control and pull out the Emergency Stop button to the position 2 Push down the Emergency Stop button to the OFF position Result No functions should operate machine should stop 3 Turn the key switch to platform control and pull out the Emergency Stop button to the oN position at both the ground and platform controls 4 Push down the platform Emergency Stop button to the orr position Result No machine functions should operate The ground Emergency Stop button will stop all machine operation even if the key switch is switched to platform control Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 4 Scheduled Maintenance Procedures B 8 Test the Ground Control Override A properly functioning ground control override is essential to safe machine operation The ground control override function is intended to allow ground personnel to operate t
276. ion burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches andother jewelry 9 Pull the 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 platform rotator hydraulic hoses at the union located on the bottom side of the primary boom 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 13 Remove the hose clamp from the side of the primary boom at the pivot end Part No 36540 Genie Z 34 22 amp Genie Z 34 22N Section 7 Repair Procedures First Edition Third Printing SECONDARY BOOM COMPONENTS 14 Remove the drive speed limit switch mounted on the side of the pivot end of the primary boom Do not disconnect the wiring 15 Attach a strap from an overhead crane to the pivot end of the primary boom 16 Carefully lift the secondary and primary boom assembly until the master and primary lift cylinder hydraulic hoses are accessible 17 Remove the cable covers from the top of the upper secondary boom 18 Tag disconnect and plug the primary boom lift cylinder and master cylinder hydraulic hoses
277. ions should operate 4 18 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 4 Scheduled Maintenance Procedures B 12 Test the Drive Enable System Proper drive enable system operation is essential to safe machine operation When the primary boom is past the non steering wheels drive movement is stopped and the indicator light turns on The drive enable toggle switch must be used to reactivate drive function and should inform the operator that the machine may move in the opposite direction that the drive and steer controls are moved An improperly functioning drive enable system may allow the machine to be moved into an unsafe position 1 Turn the key switch to platform control and pull out the Emergency Stop button to the position at both the ground and platform controls 2 Atthe platform controls rotate the turntable to the right until the primary boom is past the right non steer wheel Result The drive enable indicator light should come on and remain on while the boom is past the non steer wheel 3 Move the lift drive select switch to the drive position TABLE PROCEDURES Move the drive control handle off center Result The drive function should not operate Move and hold the drive enable toggle switch to either side and slowly move the drive control handle off center Result The drive function should operate liis ACAUTION Co
278. ir open in ground wire circuit from the boom function speed controller to ground OR replace the boom function speed controller Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Continued from page 55 Turn key switch to ground controls and pull both Emergency Stop buttons out to the ON position Z 34 22 before serial number 153 and Z34 22N before serial number 304 Move the primary boom extend retract toggle switch in the RETRACT direction and check voltage on the blk wht 8 wire primary boom retract directional valve coil item AC Z 34 22 after serial number 152 and Z 34 22N after serial number 303 Hold the function enable toggle switch to either side and move the primary boom extend retract toggle Switch in the RETRACT direction and check voltage on the blk wht 8 wire primary boom retract directional valve coil item AC or BC or CK Continued on the next page Section 5 Troubleshooting Flow Charts Z 34 22 before serial number 153 and Z34 22N before serial number 304 Move the primary boom toggle Switch in the RETRACT direction and check voltage at TB8 Z 34 22 after serial number 152 and Z 34 22N after serial number 303 Hold the function enable toggle switch to either side and move the primary boom extend retract toggle swit
279. ircuit from the boom function proportional valve coil to ground Repair open in blk red wire to wht red wire to TB6 Repair open in wire circuit through boom function toggle switches to the red wire on the boom function speed controller Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 5 Troubleshooting Flow Charts CHART 10 Press down the foot Repair open in ground switch and move the wire circuit from the primary boom toggle boom function speed switch in the DOWN controller to ground OR direction Check the replace the boom voltage at the blk red function speed wire on the boom controller function speed controller Continued from the previous page Repair open in blk red to wht red wire circuit from the boom function speed controller to TB6 Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 5 39 Section 5 Troubleshooting Flow Charts LL LES LL LL LL CHART 10 Continued from page 38 Turn key switch to ground controls and pull both Emergency Stop buttons out to the ON position 2 34 22 before serial number 153 and Z34 22N before serial number 304 Move the primary boom toggle Switch in the DOWN direction and check voltage on the red blk 2 wire at the primary boom down directional valve coil item I 2 34 22 from serial number 153 to 1733 and Z 34 22N from serial number 304 to 2226 Hold the fu
280. ircuit from TB2 to primary boom down directional valve coil OR repair open in brn ground wire circuit to manifold OV Repair open in red blk 2 wire circuit to TB2 5 40 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 5 Troubleshooting Flow Charts SS SS SS CHART 10 Continued trom the Disconnect the red blk wire to the primary ohms Replace the primary previous pag boom down directional boom down directional valve coil Test the valve coil resistance of the valve coil See Repair Section function operates Replace rue directional valves directional valve Z 34 22 before serial number 1734 and Z 34 22N before serial number 2227 items D and E Z 34 22 after serial number 1733 and Z 34 22N after serial number 2226 items AC and AB Activate the primary boom DOWN function function inoperative 2 34 22 before serial Adjust the system relief number 1734 and valve see Repair Z 34 22N before serial Section number 2227 Move the Z 34 22 before serial primary boom toggle number 1734 and Switch in the DOWN Z 34 22N before serial direction and check the number 2227 item B pressure less than Z 34 22 after serial Z 34 22 after serial 3200 PSI number 1733 and number 1733 and Z 34 22N after serial Z 34 22N after serial number 2226 item YY number 2226 Hold the OR repair or replace function enable toggle
281. irst Edition Third Printing Section 4 Scheduled Maintenance Procedures D 1 Test or Replace the Hydraulic Oil Replacement or testing of the hydraulic oil is essential for good machine performance and service life Dirty oil and suction strainers 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 The machine uses Dexron equivalent hydraulic oil 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 Perform this procedure with the boom in the stowed position When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications Z 34 22 before serial number 809 and Z 34 22N before serial number 1116 1 Remove the tank mounting fasteners Remove the tank from the power unit Table D Procedures 2 Completely drain the tank into a suitable container See capacity specifications Remove the suction strainer and the magnet and then clean the tank with mild solvent Install the suction strainer Place th
282. irst Edition Third Printing TABLE OF CONTENTS Section Five Troubleshooting Flow Charts continued 7 10 11 12 13 14 15 16 17 18 19 20 21 23 24 25 Platform Controls Inoperative Ground Controls Operate Normally Z 34 22 before serial number 1734 and Z 34 22N before serial number 2227 sse 5 27 Platform Controls Inoperative Ground Controls Operate Normally Z 34 22 after serial number 1733 and Z 34 22N after serial number 2226 5 21 Primary Boom Up Function Inoperative 2 5 34 Primary Boom Down Function Inoperative 5 38 Secondary Boom Up Function Inoperative 2 5 42 Secondary Boom Down Function Inoperative 5 46 Primary Boom Extend Function 5 50 Primary Boom Retract Function Inoperative 5 55 Turntable Rotate Left Function Inoperative 5 60 Turntable Rotate Right Function Inoperative 5 65 All Platform Level Functions Inoperative 5 69 Platform Level Up Function Inoperative 5 71 Platform Level Down Function Inoperative
283. is in the stowed position with the turntable rotated so the boom is in between the non steer wheels Be sure all other functions operate normally Turn key switch to platform controls and pull both Emergency Stop buttons out to the ON position Press down the foot switch and check voltage at TB12 24V Press down the foot switch and check voltage at terminal 14 on the drive enable limit switch LS3 24V Rotate the boom past either non steer wheel and check voltage on 24V the red 5 wire at terminal 13 of the drive enable limit switch LS3 Press down the foot 24 switch and check voltage on org blk wire at terminal 5 on drive controller Press down the foot switch and check voltage at the wht wire on the center terminal TS15 24V Press down the foot switch and hold the drive enable toggle switch TS15 to either side and check voltage at terminal 5 on the drive controller 24V Begin troubleshooting from the beginning of the chart OR consult Genie Industries Service Department Repair open in blu wht 3 wire circuit from TB12 to the wht wire on the center terminal of TS15 Repair open in the blk 5 wire from TB12 to terminal 14 on the drive enable limit switch Check for proper activation of drive enable limit switch LS3 when the boom is rotated past either non steer wheel OR replace E contact OR replace 3 Replace drive controller Repair o
284. is to be used as a guide only unless noted elsewhere in this manual Size 6 46 Class 8 8 Class 10 9 03 Class 12 9 mm Y 5 6 N e e pd N 110 120 150 170 210 240 380 420 m 8 A DR DRY 854 775 91 105 132 DRY DRY 30 78 1055 682 925 909 1232 ow 1 ile c 5 i c 5 js 5 1 M P D A a a Ol lt eJ Oj Do ey 9 O O1 j m o gt oA p o T NI zi o E r c 00 8 E lt r c 0 8 lt 00 8 00 i Poy m 9 Hig o Q gt E x T A e z e zi zi e N P en EF BEN Oy OY MNI 0 oo A oj A O Oo NI TC 4 AI N 4 CO N oO n AR Oy A o m OW co APY OTN No fon BN olo E OTR o STA IS Oto Afro DON o 91 A o o o o j gt Copco NI ofo o Co fro NIN o OO fN NI
285. ise to increase the voltage or counterclockwise to decrease the voltage 7 Turn the boom function speed controller to the 9 position 8 Setthe max out Press down the foot switch then move the primary boom toggle switch to the pown position Adjust the voltage to 15 5V DC Turn the max out trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage If equipped 9 Setthe ramp rate Turn the ramp rate trimpot to obtain a 2 second delay from 0 to 15 5V DC Turn the trimpot clockwise to increase the time or counterclockwise to decrease the time a black red wire b diode c white red wire Boom function speed d boom function speed controller controller specifications e maxouttrimpot f thresholdtrimpot Threshold 8V DC controller turned to cREEP Max out 15 5V DC controller turned to 9 Ramp 2 seconds controller turned to 9 Added after serial numbers Z34 1924 Z34N 2553 7 8 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 7 Repair Procedures 1 2 Foot Switch How to Test the Foot Switch PLATFORM CONTROLS 3 Press down the foot switch Connect the leads from an ohmmeter or continuity tester to each wire combination listed below and check for continuity Test Desired result 1 Turn the key switch to the orr position and separate the wiring quick disconnect plug from red to
286. itch in the UP direction and check voltage at TB43 2 34 22 after serial number 152 and Z34 22N after serial number 303 Hold the function enable toggle Switch to either side and move the jib toggle switch in the UP direction and check voltage at 43 Turn key switch to platform controls and pull both Emergency Stop buttons out to the ON position With the boom function speed controller turned to 9 press down the foot switch and move the jib toggle switch in the UP direction Check voltage on the blk jib wire at jib up directional valve coil 20V or more Troubleshoot jib function toggle switch on ground controls OR replace diode on toggle switch OR repair open in grn 1 to blk jib wire circuit from toggle switch to boom function directional valve coil OR consult Genie Industries Service Department 20V or more CHART 22 Repair open in the grn 1 to blk jib wire circuit from TB43 to the jib up directional valve coil OR repair open in the ground wire circuit to valve coil Troubleshoot jib toggle switches on ground and platform controls OR replace diodes on toggle switches OR repair open grn 1 to blk jib wire circuit from toggle switches to jib up directional valve coil OR consult Genie Industries Service Department If voltage to boom function directional valve coil from ground toggle switch and platform toggle switch has been restored and jib up function is still inoperati
287. l DRIVE ENABLE WHT ORG RED RED WHT g TRAVEL ALARM BRAKE RELEASE N C VALVE TS15 87 A 30 JP1 REMOVE FOR CE VERSION RELEASE BRAKE JACK RED WHT TB48 BRAKE RELEASE N O VALVE RED RED WHT 48 dl RED WHT 48 E RED WHT BRAKE PRESSURE EH SWITCH m BLU SSS STEER LEFT TB36 BLU 1 10 BLU BLK 1 BLU BLK 37 ur DRIVE STEER 5 fet STEER RIGHT v Y Y wek G HOUR METER AUXILIARY PUMP CONTACTOR RELAY ORG RED CONTROL BOX GROUND Yl ne ewo AUX PUMP RED RED 27 9 8 gt TS51 RED GRN WHT 19 i pwz RED 1 CR20 GRNWHT 8 8 LIFT PUMP CONTACTOR RELAY p PR2 E PRIMARY 8 5 LIFT PUMP pes OPTION ORG RED 48V TB19 GRNWHT3 GRNWHT 8 DISCHARGE TO N PR3 AUXILIARY LIFT PUMP Spo RED BRN Eres s WHT RED 3 PROPORTIONAL FLOW CONTROL WHT RED 6 He SET TO RED RED GRN BLK RED GRN WHT 19 BLK E s 585 BRN JIB z 9 JIB BOOM UP TB43 1 JIB BOOM DOWN
288. l number 153 Z 34 22N before serial number 304 Do not adjust the controllers unless the static battery supply voltage is above 24V DC This procedure will require the use of two multi meters One will be used for measuring amperage and the other for voltage AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Individual trim potentiometers trimpots are used to adjust various output signals from the drive and boom function speed controllers The trimpots will be identified as the following Max out trim potentiometer max out trimpot e High range trim potentiometer max out trimpot Lorange trim potentiometer lo range trimpot Dual range trim potentiometer lo range trimpot Threshold trim potentiometer threshold trimpot e Ramp rate trim potentiometer ramp rate trimpot 1 Block the steering wheels 2 Center a lifting jack of ample capacity 15000 Ibs 6804 kg under the drive chassis between the non steering wheels 7 2 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 7 Repair Procedures 4 A Lift the wheels off the ground approximately 1 to 2 inches 2 5 to 5 cm and place jack stands under the drive chassis for support Open the platform control box lid and locate the brake controller printed circuit board
289. l 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 any forklift overhead crane or d 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 ihe fasteners intended for one 7 time use i e cotter pins and self locking nuts are not reused These components may fail if they are used a second time Be sure to properly dispose of old oil or Yellow without safety alert P other fluids Use an approved container CAUTION symbol used to indicate the aw Please be environmentally safe presence of a potentially hazardous situation which if not n Be sure that your workshop or work area avoided may result in property JJ is properly ventilated and well lit damage SAIS Indicates special operation or maintenance information iv Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Power Source The Genie Z 34 22 amp Genie Z 34 22N are powered by eight six volt 315 AH batteries separated into two groups of four Each group of four batteries is wired in series to produce 24V DC The two battery groups are then joined to produce 48V DC The drive system uses 48V DC and the control system uses 24V DC Hydraulic System All mac
290. latform controls and pull both Emergency Stop buttons out to the ON position Press down the foot switch and press the steer rocker switch in the RIGHT direction and check voltage on TB37 20V or more Press down the foot switch and press the steer rocker switch in the RIGHT direction and check voltage on TB19 20V or more Press down the foot switch and press the 20V or steer rocker switch in more the RIGHT direction and check voltage on blu blk 37 wire at the steer right directional valve coil item on the steer brake manifold ov Repair open in blu blk 37 wire circuit from TB37 to the steer right directional valve coil Press down the foot switch and press the steer rocker switch in the RIGHT direction and check voltage at the drive controller terminal where the blu blk 1 wire is attached 20V or more Repair open in blu blk 1 wire circuit from the drive controller to TB36 Repair open in wire circuit with diode from TB37 to TB19 Disconnect the wires ae from the steer right ohms directional valve coil Test the resistance of the valve coil See Repair Section 20 to 25 ohms Install a 0 to 3000 PSI 0 to 207 bar pressure gauge at the quick isconnect coupling on the boom function T manifold Press down the foot switch and press the steer rocker switch in the RIGHT direction and check the pressure less than 3200 PSI Repair or replace steer cylinder
291. le switch in the LEFT direction and check the ressure 34 22 after serial number 152 and Z34 22N after serial number 303 Hold the function enable toggle Switch to either side and move the turntable rotate toggle switch in the LEFT direction and check the pressure Adjust the system relief valve see Repair Section item AB or BB or CR OR repair or replace the turntable rotation motor OR function manifold could have an internal defect Consult Genie Industries Service Department less than 3200 PSI First Edition Third Printing Check for mechanical restrictions keeping the turntable rotate left function from operating OR repair or replace the turntable rotation motor OR consult Genie Industries Service Department 5 64 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 5 Troubleshooting Flow Charts Turntable Rotate Right Function Inoperative Be sure key switch is in the appropriate position Be sure the Emergency Stop buttons are pulled up to the oN position Be sure the battery packs are properly connected and fully charged Turn key switch to ground controls and pull both Emergency Stop buttons out to the ON position 2 34 22 before serial number 153 and Z34 22N before serial number 304 Move the turntable rotate toggle switch TS10 in the RIGHT direction and check voltage on the wht red 6 wire at the boom function pro
292. le switch to either side and move the primary boom extend retract toggle switch in the RETRACT direction and check voltage at terminal 30 on CR3 2 34 22 from serial number 153 to 1733 and Z 34 22N from serial number 304 to 2226 Replace CR2 2 34 22 after serial number 1733 and 2 34 22 after serial number 2226 Replace CR3 First Edition Third Printing Z 34 22 from serial number 153 to 1733 and Z 34 22N from serial number 304 to 2226 Repair open in grn wht wire circuit from TB19 to terminal 6 on CR2 OR repair open in the wire circuit from the key switch ground control contact to the function enable switch to the function switch wire circuit with diode to TB19 OR replace diode OR replace primary boom extend retract toggle switch OR contact Genie Industries Service Department 2 34 22 after serial number 1733 and Z 34 22N after serial number 2226 Repair open in grn wht wire circuit from TB19 to terminal 30 on CR3 OR repair open in the wire circuit from the key switch ground control contact to the function enable switch to the function switch wire circuit with diode to TB19 OR replace diode OR replace primary boom extend retract toggle switch OR contact Genie Industries Service Department Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 5 Troubleshooting Flow Charts Auxiliary Pump Motor Will Not Operate Be sure all other functi
293. leshooting Flow Charts 13 Press down the foot Repair open in wire switch and move the circuit through boom primary boom extend function toggle switches retract toggle switch in to the red wire on the the EXTEND direction boom function speed Check voltage at the red controller wire on the boom function speed controller Continued from the previous page Press down the foot Repair open in ground switch and move the wire circuit from the primary boom extend boom function speed retract toggle switch in controller to ground OR the EXTEND direction replace the boom Check voltage at the blk function speed red wire on the boom controller function speed controller Repair open in blk red to wht red wire from the boom function speed controller to TB6 Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 5 51 Section 5 Troubleshooting Flow Charts First Edition Third Printing CHART 13 Turn key switch to ground controls and pull both Emergency Stop buttons out to the position Z 34 22 before serial number 153 and Z34 22N before serial number 304 Move the primary boom extend retract toggle switch in the EXTEND direction and check voltage on the blk 7 wire primary boom extend directional valve coil item AT 2 34 22 from serial number 153 to 1733 and Z 34 22N from serial number 304 to 2226 Hold the function enable toggle switch to either side and move the pri
294. ll Drive Functions Inoperative All Other Functions Operate Normally Z 34 22 after serial number 1733 and Z 34 22N 2226 5 110 Motor Controller Fault Code 21 Throttle Fault Z 34 22 after serial number 1733 and Z 34 22N after serial number 2226 sss 5 112 Motor Controller Fault Code 32 Main Contactor Welded Z 34 22 after serial number 1733 and Z 34 22N after serial number 2226 sss 5 113 Motor Controller Fault Code 34 Missing Main Contactor OR Main Contactor Did Not Close Z 34 22 after serial number 1733 and Z 34 22N after serial number 2226 sse 5 114 Brake Release Function Inoperative Z 34 22 after serial number 1733 and Z 34 22N after serial number 2226 sss 5 117 Part No 36540 Genie Z 34 22 amp Genie Z 34 22N Xi First Edition Third Printing TABLE OF CONTENTS Section Five Troubleshooting Flow Charts continued 31 32 37 39 Drive Forward Function Inoperative 5 120 Z 34 22 before serial number 1734 and Z 34 22N before serial number 2227 Drive Reverse Function Inoperative 5 121 Z 34 22 before serial number 1734 and Z 34 22N before serial number 2227 Machine Will Not Drive At Full Speed Z 34 22 before serial number 1734 and Z 34 22N before 2227 5 122 Machine Will Not D
295. llision hazard Always use the 6 7 color coded direction arrows the platform control panel and the drive chassis to identify which direction the machine will travel Rotate the turntable to the left until the primary boom is past the left steer wheel Result The drive enable indicator light should come on Repeat steps 3 through 5 Part No 36540 Genie 7 34 22 amp Genie Z 34 22N 4 19 Section 4 Scheduled Maintenance Procedures First Edition Third Printing TABLE B PROCEDURES B 13 Test the Drive Brakes Proper brake action is essential to safe machine operation The drive brake function should operate smoothly free of hesitation jerking and unusual noise Hydrostatic brakes and hydraulically released individual wheel brakes can appear to operate normally when not fully operational Collision hazard Be sure that the AWARNING machine is not in free wheel or partial free wheel configuration Refer to B 4 in this section Confirm the Proper Brake Configuration Select a test area that is firm level and free of obstructions 1 Mark a test line on the ground for reference 2 Lowerthe boom into the stowed position 3 Turn the key switch to platform control and pull out the Emergency Stop button to the position at both the ground and platform controls 4 Move the lift drive switch to the prive position if equipped 5 Choose a point on the machine i e contact patch of a tire
296. lly lowered Observe the pressure reading on the pressure gauge Primary boom down relief valve specifications Before serial number Z34 22 2901 Z34 22N 3533 Pressure 1400 psi 97 bar After serial number Z34 22 2900 Z 34 22N 3532 Pressure 1600 psi 110 bar MANIFOLDS 4 Turnthe machine off Hold the relief valve and remove the cap Z 34 22 Before serial number 674 item AS From serial number 674 to 1733 item BS After serial number 1733 item CF Z 34 22N Before serial number 935 item AS From serial number 935 to 2226 item BS After serial number 2226 item CF 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 AWARNING 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 Part No 36540 Genie Z 34 22 amp Genie Z 34 22N Section 7 Repair Procedures First Edition Third Printing MANIFOLDS How to Adjust the Secondary Boom Down Relief Valve Perform this procedure with the boom in the stowed position 1 Connect a 0 to 3000 psi 0 to 206 bar pressure gauge to the test port on the function manifold 2 Turn the key switch to ground control and pull out the Emergency Stop button to the position 3 Z 34 22 before serial number 153 and Z 34 22N before serial number
297. lt Code Programmer Condition Possible Causes Diagnostic Display Fault Indicator Light is OFF or is ON but not blinking COMMUNICATION ERROR Machine will not drive Controller fault indicator light may or may not be on at the platform controls 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 Emergency Stop button to the OFF position and wait for 5 seconds Pull out the ground control Emergency Stop button to the ON position If problem persists replace the motor controller f Nmaoewaen HW FAILSAFE 1 2 3 M SHORTED FIELD OPEN ARM SENSOR FLD SENSOR Machine will not drive Controller fault indicator light on at the platform controls Machine will not drive Controller fault indicator light on at the platform controls Machine will not drive Controller fault indicator light on at the platform controls Machine will not drive Controller fault indicator light on at the platform controls Machine will not drive Controller fault indicator light on at the platform controls The motor controller failed self test The motor controller has an internal short between M and B terminals Motor wiring is loose OR motor is defective OR motor controller has an internal short Defective motor controller Defective motor controller Replace
298. lts Carefully remove the pump HYDRAULIC PUMPS How to Remove the Main Function Pump Z 34 22 after serial number 809 and Z 34 22N after serial number 1116 1 Tag disconnect and plug the hoses from the main function pump 2 Remove the pump mounting bolts from the pump Carefully remove the pump from the electric motor Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 7 39 Section 7 Repair Procedures First Edition Third Printing Manifolds 8 1 Function Manifold Components Z 34 22 before serial number 674 and Z 34 22N before serial number 935 The function manifold is mounted to the turntable under the ground controls Index Schematic No Description Item Function Torque 1 Differential sensing valve AA Differential sensing circuit 10 12 ft lbs 14 16 Nm 2 Relief valve 3200 psi 221 bar AB System 25 30 ft Ibs 34 41 Nm 3 2 position way solenoid valve AC Boom fetract 8 10 ft lbs 11 14 Nm 4 2 position way solenoid valve AD Primary boom up 8 10 ft Ibs 11 14 Nm 5 2 position way solenoid valve AE Secondary boom up 8 10 ft lbs 11 14 Nm 6 2 position way solenoid valve AF Turntable rotate left 8
299. lve after installing the hydraulic tank Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 4 Scheduled Maintenance Procedures 18 Operate all machine functions through a full cycle and check for leaks 19 Check oil level Torque specification 1 20 fasteners 5 ft lbs 6 8 Nm Hydraulic Oil Specifications Z 34 22 before serial number 809 and Z 34 22N before serial number 1116 Hydraulic tank capacity 5 gallons 18 9 liters Hydraulic system including tank 7 gallons 26 5 liters Z 34 22 after serial number 808 and Z 34 22N after serial number 1115 Hydraulic tank capacity 4 gallons 15 1 liters Hydraulic system including tank 6 gallons 22 7 liters TABLE D PROCEDURES D 2 Grease the Steer Axle Wheel Bearings 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 steering wheels then center a lifting jack under the steer axle 3 Raise the machine approximately 6 inches 15 cm and place blocks under the drive chassis for support 4 Remove th
300. ly closed poppet valve Erren Brake 22 25 30 ft lbs 34 41 Orifice washer 0 052 inch 1 32 M Brake circuit Check valeiros esen uis Brake circuit ccs 25 30 ft lbs 34 41Nm Proportional solenoid valve Ni assu Brake 10 12 ft lbs 14 16Nm Q9 eo OG Refer to previous page for Plug Torque and Valve Coil Specifications Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 7 55 Section 7 Repair Procedures First Edition Third Printing Hydraulic Tank 9 1 Hydraulic Tank The primary functions of the hydraulic tank are to cool clean and deaerate the hydraulic fluid during operation It utilizes internal suction strainers for the pump supply lines and has a return filter mounted inside the reservoir Component damage hazard CAUTION The work area and surfaces where this procedure will be performed must be clean and free of debris that could get into the hydraulic system When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications How to Remove the Hydraulic Tank Z 34 22 before serial number 809 and Z 34 22N before serial number 1116 1 Open the tank side turntable
301. m bellcrank from the boom Crushing hazard The jib boom AWARNING bellcrank may become unbalanced and fall when the pins are removed if it is not properly supported and secured to the lifting device JIB BOOM COMPONENTS 3 2 Jib Boom Bell Crank How to Remove the Jib Boom Bell Crank Perform this procedure with the boom in the stowed position When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Remove the platform See 2 1 How to Remove the Platform 2 Remove the Jib Boom See 3 1 How to Remove the Jib Boom 3 Support and secure the jib boom bell crank to an appropriate lifting device 4 Remove the pin retaining fasteners from the slave cylinder rod end pivot pin Do not remove the pin 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 a soft metal drift to remove the slave cylinder rod end pivot pin 7 Remove the jib boom bell crank from the extension boom Crushing hazard The jib boom AWARNING bell crank may become unbalanced and fall when the pins are removed if it is not properly supported and secured to the lifting device Part No 36540 Genie Z 34 22 amp Genie Z 34 22N Section 7 Repair Procedures First Edition Thi
302. mary boom extend retract toggle switch TS63 in the EXTEND direction and check voltage on the wht red 6 wire at the boom function proportional valve coil item AU or BU or CH 24N Continued on page 52 2 34 22 before serial number 153 and 234 22 before serial number 304 Move the primary boom extend retract toggle switch in the EXTEND direction and check voltage at TB6 2 34 22 after serial number 152 and Z34 22N after serial number 303 Hold the function enable toggle switch to either side and move the primary boom extend retract toggle switch in the EXTEND direction and check voltage at TB6 Turn key switch to platform controls and pull both Emergency Stop buttons out to the ON position With the boom function speed controller turned to 9 press down the foot switch and move the primary boom extend retract toggle switch 2 34 22 before serial number 1734 and Z 34 22N before serial number 2227 TS4 Z 34 22 after serial number 1733 and Z 34 22N after serial number 2226 TS13 in the EXTEND direction Check voltage at TP6 ov Continued on the next page 24V Repair open in wht red 6 wire circuit from TB6 to boom function proportional valve coil OR repair open in brn ground wire circuit to boom function proportional valve coil 24V Repair open in blk red wire to TB6 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 5 Troub
303. mary boom extend retract toggle switch in the EXTEND direction and check voltage on the blk 7 wire primary boom extend directional valve coil item BT Z 34 22 after serial number 1733 and Z 34 22N after serial number 2226 Hold the function enable toggle switch to either side and move the primary boom extend retract toggle switch in the EXTEND direction and check voltage on the blk 7 wire primary boom extend directional valve coil item CK Continued from page 50 24V Continued on the next page Z 34 22 before serial number 153 and Z34 22N before serial 24V number 304 Move the secondary boom toggle switch in the EXTEND direction and check voltage at TB7 Z 34 22 after serial number 152 and Z34 22N after serial number 303 Hold the function enable toggle switch to either side and move the primary boom extend retract toggle switch in the EXTEND direction Check the voltage at TB7 Turn key switch to oV Repair open blk 3 platform controls and wire circuit to TB7 pull both Emergency Stop buttons out to the ON position With the boom function speed controller turned to 9 press down the foot switch and move the primary boom extend retract toggle switch Z 34 22 before serial number 1734 and Z 34 22N before serial number 2227 TS4 2 34 22 after serial number 1733 and Z 34 22N after serial number 2226 TS13 in the EXTEND direction Check voltage at TB7 Repair open in blk 7 wire ci
304. mber 935 to 2226 The function manifold is mounted to the turntable under the ground controls Index Schematic No Description Item Function Torque 1 Differential sensing valve BA uus Differential sensing circuit 10 12 ft Ibs 14 16 Nm 2 Relief valve 3200 psi 221 bar BB System 25 30 ft lbs 34 41 Nm 3 2 position 3 way solenoid valve Boom retract ceci 8 10 ft lbs 11 14 Nm 4 2 position 3 way solenoid valve BD us Primary boom 8 10 ft lbs 11 14 Nm 5 2 position 3 way solenoid valve BE Secondary boom 8 10 ft Ibs 11 14 Nm 6 2 position 3 way solenoid valve BF Turntable rotate left 8 10 ft lbs 11 14 Nm 7 2 position 3 way solenoid valve BG Platform level 8 10 ft lbs 11 14 Nm 8 2 position 3 way solenoid valve BH Boom extend 8 10 ft lbs 11 14 Nm 9 2 position 3 way solenoid valve Bl ks Primary boom down 8 10 ft Ibs 11 14 Nm 10 2 position way solenoid valve BJ ie Secondary boom down 8 10 ft lbs 11 14 Nm 11 2 position 3 way solenoid valve BK Turntable rotate right
305. mergency Stop button to the position Move the primary boom up toggle switch in the up direction Z 34 22 after serial number 152 and Z 34 22N after serial number 303 Turn the key switch to ground controls and pull out the Emergency Stop button to the oN position Hold the function enable toggle switch to either side and move the primary boom up toggle switch in the up direction 5 Inspect the filter and related components to be sure that there are no leaks Clean up any oil that may have spilled during the replacement procedure Properly discard the oil Z 34 22 after serial number 809 and Z 34 22N after serial number 1116 1 Cleanthe area around the oil filter housing located on top of the tank 2 Remove the oil filter housing cover fasteners then remove the cover Remove the oil filter element from the housing 4 Clean the oil filter housing with a mild solvent Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 4 Scheduled Maintenance Procedures ee TABLE B PROCEDURES 5 Install the new oil filter element 6 Install the oil filter housing cover and tighten the fasteners 7 Turn the key switch to ground controls and pull out the Emergency Stop button to the oN position Hold the function enable toggle switch to either side and move the primary boom up toggle switch in the up direction 8 Inspect the filter and related components to be sure
306. minal 85 on CR20 Z 34 22 from serial Z 34 22 from serial number 153 to 1733 number 153 to 1733 and Z 34 22N from and Z 34 22N from serial number 304 to serial number 304 to 2226 Hold the function 2226 Repair open in enable switch to either the grn wht wire circuit side and move the from terminal 2 on primary boom extend CR2 retract toggle switch in Z 34 22 after serial the RETRACT direction number 1733 and and check voltage at Z 34 22N after serial terminal 2 on CR2 number 2226 Repair Z 34 22 after serial open in the grn wht wire number 1733 and circuit from terminal Z 34 22N after serial 387A on to terminal number 2226 Hold the 85 CR20 function enable switch to either side and move the primary boom extend retract toggle switch in the RETRACT direction and check voltage at terminal 287A on Continued on the next page Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 5 15 Section 5 Troubleshooting Flow Charts CHART 2 Continued from the previous page 2 34 22 from serial number 153 to 1733 and Z 34 22N from serial number 304 to 2226 Hold the function enable switch to either side and move the primary boom extend retract toggle switch in the RETRACT direction and check voltage at terminal 6 on CR2 2 34 22 after serial number 1733 and 2 34 22 after serial number 2226 Hold the function enab
307. mm C Platform rotate circuit Before serial number 234 22 1892 and Z34 22N 2548 Orifice plug 0 022 inch 0 56 mm From serial number Z34 22 1892 to 2005 and Z34 22N 2548 to 2771 Solenoid valve 2 position way IDs iioc Platform rotate 8 10 ft lbs 11 14 Nm 5 Solenoid valve 2 position way E umm Jib boom down 8 10 ft Ibs 11 14 Nm 6 Orifice plug 0 030 inch 0 89 mm F Jib boom platform rotate circuit 2 2 6 e 4 es 215 J gr QS Plug Torque Specifications Valve Coil Resistance Specification Description Hex Size Torque Description Measurement SAE No 2 1 8 50 in Ibs 6 Nm 2 position 3 way valve 20V 23 5 to 24 50 SAE No 4 3 16 13 ft lbs 18 Nm schematic items A B D and E 7 52 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 7 Repair Procedures D T nst nc M n i MANIFOLDS 8 7 Jib Boom Platform Rotate Manifold Components Z 34 22 after serial number 2005 and Z 34 22N after serial number 2771 The jib boom platform rotate manifold is mounted to the jib boom 1 Solenoid valve 3 position 4 way Eu Jib boom
308. mo 0 032 Pump rn 0 81 mim ONE Ho 0 5 GPM 1 7 GPM 207 bar TURNTABLE 1 9 L min 6 4 L min 81 ROTATE M xeu ee 2500 PSI 2500 PSI 4 Z 172 bar 172 bar MICRON MASTER 59 CU IN asl DTE UNES 21 5 IET lt lt CYLINDER IREV E ue L1 o o NI HIM Mo TANK 4 GALLON s 1 V N T di 15 1 Liters 1109 11 3000 PSI 3000 PSI 2500 PSI l as 57 s Pan JIB UP DOWN 6 m PLATFORM ROTATE P1 G1 C1 C2 M1 M2 C3 C4 C5 C6 C7 C8 MANIFOLD 0 025 bo omn opeq cc EC d loe ed c bebe n mh qp T2 PR1 0 76 PR2 FUNCTION a ge PEG CES E E _ 2 MANIFOLD 60 E EN eL 5 i ME HUM e ME HLM ess el 1800 PSI Lon gt x D 221 bar 1 110 bar 96 bar 124 bar i lt 7 amp EX x LES 3000 PSI 1500 PSI EE MICRON 68 4 25 PSI 1 7 bar ENG E 1 0058 FM I wi Bs ws Bs LE M B s I E Mr lu MS un LN P oni UMEN NUN 1 89 8 8 85 8 80 4 8 pd ORFICE ADDED 234 22 AFTER SERIAL NUMBER 781 0 050 Z34 22N AFTER SERIAL NUMBER 1030 1 27 1 iT2 Part No 36540 Genie Z 34 22 am
309. motor controller harness connector from the motor controller Connect the leads from an ohmmeter to pins 14 and 16 on the connector pins 14 and 16 are the wht red and red wht wires Check the resistance 4000 to 7500 ohms Block the steer wheels and raise the machine so drive tires are off the ground With the leads from an ohmmeter connected to pins 14 and 16 on the connector move the drive controller slowly to full stroke in both the FORWARD and REVERSE directions while watching the ohm meter Does the resistance ramp smoothly down to 10 ohms or less in both directions Note This will require 2 people Begin troubleshooting from the beginning of the chart OR consult Genie Industries Service Department Repair open in the wire circuit from the potentiometer to terminals1 and 2 on the drive controller OR replace the drive controller Repair open in the ground wire circuit in the red wht or wht red wires from pins 14 and 16 to terminals 1 and 2 on the drive controller OR replace the drive controller Replace the drive controller 5 112 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 5 Troubleshooting Flow Charts Motor Controller Fault Code 32 Main Contactor Welded Z 34 22 after serial number 1733 and Z 34 22N after serial number 2226 Troubleshooting drive function faults may also be accomplished by usin
310. mp LER See EE l L l lt 3 a E al E E E 5 8 i Ro es N Lo M Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 6 15 Z 34 22 Control Relay CR5 was added after serial number 551 Section 6 Schematics Z 34 22N Control Relay CR5 was added after serial number 689 Electrical Schematic 7 34 22 from serial number 153 to 1733 Z 34 22N from serial number 304 to 2226 First Edition Third Printing 9 Lx BLU RED 3 B WHT 13 3 BRN H DRIVE ENABLE diii BLU WHT 3 BLK I2 RED 16 a ORG RED 3 5 4 ORG BLK 1 RED 12 i HOUR METER TM LE fad FERR ES alg
311. mproper hydraulic oil levels can damage hydraulic components Daily checks allow the inspector to identify changes in oil level that might indicate the presence of hydraulic System problems Z 34 22 before serial number 572 and Z 34 22N before serial number 572 1 Besure that the boom is in the stowed position 2 Remove the breather cap with dipstick from the hydraulic tank 3 Visually inspect the dipstick Result The hydraulic oil level should be at the FULL mark on the dipstick Z 34 22 from serial number 572 to 808 and Z 34 22N from serial number 572 to 1115 1 Be sure that the boom is in the stowed position then visually inspect the sight glass on the hydraulic tank Result The hydraulic oil level should be within the top and bottom of the sight glass Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 4 3 Section 4 Scheduled Maintenance Procedures First Edition Third Printing TABLE A PROCEDURES Z 34 22 after serial number 808 and Z 34 22N after serial number 1115 1 Besure that the boom is in the stowed position 2 Visually inspect the hydraulic tank Result The hydraulic oil level should be within the FULL and app marks on the hydraulic tank Hydraulic Oil Specifications Hydraulic oil type Dexron equivalent Z 34 22 before serial number 809 and Z 34 22N before serial number 1116 Hydraulic tank capacity 5 gallons 18 9 liters Hydraulic system 7 gallons in
312. mproperly functioning limit switches will allow the boom to raise and or drive into an unsafe position Drive Speed Limit Switches 1 With the boom in the stowed position visually inspect the drive speed limit switches for the following Broken or missing rollers or arms Missing fasteners Loose wiring a primary boom drive speed limit switch LS2 Z 34 22 after serial number 367 and Z 34 22N after serial number 540 b boom extend drive speed limit switch LS1 secondary boom drive speed limit switch LS4 Z 34 22 after serial number 366 and Z 34 22N after serial number 539 d boom drive speed limit switch LS2 Z 34 22 before serial number 367 and Z 34 22N before serial number 540 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 4 Scheduled Maintenance Procedures 2 Extend the primary boom approximately 12 inches 30 cm 3 Manually activate the boom extend drive speed limit switch Result The drive speed limit switch arm should move freely and spring return to center A distinct click should be felt and heard 4 Fully retract the primary boom 5 Z 34 22 and Z 34 22N machines manufactured before May 1999 Remove the rear turntable cover mounting fasteners then remove the cover Manually activate the secondary boom drive speed limit switch Z 34 22 and Z 34 22N machines manufactured after
313. n and check voltage on the org 15 wire on the platform level up directional valve coil item AL or BL or CB 24V Continued on the next page Z 34 22 before serial number 153 and Z34 22N before serial number 304 Move the platform level toggle Switch in the DOWN direction and check voltage at TB15 2 34 22 after serial number 152 and Z34 22N after serial number 303 Hold the function enable toggle Switch to either side and move the platform level toggle switch in the DOWN direction and check voltage at TB15 Turn key switch to platform controls and pull both Emergency Stop buttons out to the ON position With the boom function speed controller turned to 9 press down the foot switch and move the platform level toggle switch Z 34 22 before serial number 1734 and Z 34 22N before serial number 2227 55 Z 34 22 after serial number 1733 and Z 34 22N after serial number 2226 TS9 in the DOWN direction Check voltage at TB15 ov Repair open in power supply wiring to platform level toggle switch at ground controls OR platform controls 24V Repair open in org blk 15 wire circuit from TB15 to platform level down directional valve coil OR repair open in brn ground wire circuit to the manifold 24V Repair open in org blk 15 wire to TB15 5 78 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 5 Troubleshooting Flow Charts
314. n stowed position Turntable rotated with the boom between the non steering wheels Key switch in the orr position with the key removed Wheels chocked Before Troubleshooting Read understand and obey the safety rules and operating instructions printed in the Genie 2 34 22 amp Z 34 22N Operator s Manual Be sure that all necessary tools and test equipment are available and ready for use Read each appropriate flow chart thoroughly Attempting shortcuts may produce hazardous conditions Be aware of the following hazards and follow generally accepted safe workshop practices ADANGER Crushing hazard When testing or replacing any hydraulic component always support the structure and secure it from movement AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 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 Perform all troubleshooting ona firm level surface Two persons will be required to safely perform some troubleshooting procedures Part No 36540 Genie 7 34 22 amp Genie Z 34 22N 5 1 Section 5 Troubleshooting Flow Charts First Edition Third Printing TROUBLESHOOTING FLOW CHARTS About
315. n the non steering wheels Key switch in the orr position with the key removed e Wheels chocked 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 personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Sr Red used to indicate the presence of an imminently hazardous situation which if not avoided will result in death or serious injury Orange used to indicate the AWARNING presence of a potentially hazardous situation which if not avoided could result in death or serious injury Yellow with safety alert symbol ACAUTION used to indicate the presence of a potentially hazardous situation which if not avoided may cause minor or moderate injury Yellow without safety alert symbol used to indicate the presence of a potentially hazardous situation which if not avoided may result in property damage CAUTION Green used to indicate operation or maintenance information Indicates that a specific result is expected after performing a series of steps Part No 36540 Genie 2 34 22 amp Genie Z 34 22N 4 1 Section 4 Scheduled Maintenance Procedures First Edition Third Printing
316. nction enable toggle switch to either side and move the primary boom toggle Switch in the down direction and check voltage on the red blk 2 wire at the primary boom down directional valve coil item 1 Z 34 22 after serial number 1733 and Z 34 22N after serial number 2226 Hold the function enable toggle switch to either side and move the primary boom toggle switch in the down direction and check voltage on the red blk 2 wire at the primary boom down directional valve coil item AC 24V Continued on the next page First Edition Third Printing Z 34 22 before serial number 153 and Z34 22N before serial 24V number 304 Move the primary boom toggle switch in the DOWN direction and check voltage at TB2 Z 34 22 after serial number 152 and Z34 22N after serial number 303 Hold the function enable toggle switch to either side and move the primary boom toggle switch in the down direction and check voltage at TB2 Turn key switch to platform controls and pull both Emergency Stop buttons out to the ON position With the boom function speed controller turned to 9 press down the foot switch and move the primary boom toggle switch in the DOWN direction Check voltage at TB2 24V Troubleshoot the primary boom toggle switch OR replace diode on toggle switch OR repair open in red blk 2 wire circuit from toggle switch to TB2 OR replace toggle switch Repair open red blk 2 wire c
317. nder 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 Lift Cylinder AWARNING 2 dlly 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 When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Rotate the turntable to the side until the boom is centered between the steer and non steer tires 2 Raise the primary boom to full height Do not extend it SECONDARY BOOM COMPONENTS Attach the strap from an overhead crane to the lug on the rod end of the secondary boom lift cylinder From the bottom side of the cylinder remove the retaining fasteners from the secondary boom lift cylinder barrel end pivot pins Use a slide hammer to remove the barrel end pins access the pins from the access holes in the bulkheads one on each side Remove the pin retaining fastener from the secondary boom lift cylinder rod end pivot pin Use a soft metal drift to remove the pin Carefully lower
318. ng Chart 20 Platform Rotate Left Function inoperative Be sure key switch is in the appropriate position Be sure the Emergency Stop buttons are pulled up to the on position Be sure the battery packs are properly connected and fully charged Turn key switch to ground controls and pull both Emergency Stop buttons out to the ON position 2 34 22 before serial number 153 and Z34 22N before serial number 304 Move the platform rotate toggle switch TS15 in the LEFT direction and check the voltage on the wht red 6 wire at the boom function proportional valve coil item AU Z 34 22 from serial number 153 to 1733 and Z 34 22N from serial number 304 to 2226 Hold the function enable toggle switch to either side and move the platform rotate toggle switch TS15 in the LEFT direction and check the voltage on the wht red 6 wire at the boom function proportional valve coil item AU or BU Z 34 22 after serial number 1733 and Z 34 22N after serial number 2226 Hold the function enable toggle switch to either side and move the platform rotate toggle switch TS57 in the LEFT direction and check the voltage on the wht red 6 wire at the boom function proportional valve coil item CH Continued on page 82 2 34 22 before serial number 153 and 234 22 before serial number 304 Move the platform rotate toggle Switch in the LEFT direction and check the voltage at TB6 2 34 22 after serial numb
319. ngly recommended When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Raise the primary boom enough to access the primary boom lift cylinder rod end pivot pin 2 Attach an overhead crane to the primary boom for support Do not lift it 3 Remove the pin retaining fastener from the ground controls side upper compression arm pivot pin 5 9 PRIMARY BOOM COMPONENTS Place a block of wood across the upper secondary boom to support the cylinder when the rod end pivot pin is removed Place a rod through the compression arm pivot pin and twist to remove the pin Lower the compression arm down Support the primary boom lift cylinder with a lifting device Remove the pin retaining fastener from the primary boom lift cylinder rod end pivot pin Then use a soft metal drift to remove the pin Lower the rod end of the cylinder onto the blocks that were placed on the upper secondary boom Tag disconnect and plug the primary boom lift 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 Part No 36540 Genie Z 34 22
320. nt movement in the event of a hydraulic line failure How to Remove the 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 When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Raise the primary boom to the horizontal position Extend the boom approximately 3 to 4 feet 0 9 to 1 2 m until the extension cylinder rod end pivot pins are accessible PRIMARY BOOM COMPONENTS Remove the external snap rings from the extension cylinder rod end pivot pins Use a soft metal drift to remove the pins Remove the front counterweight cover Raise the secondary boom until the master cylinder rod end pivot pin is accessible Remove the 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 the extension cylinder removal Tag disconne
321. o manifold ov Repair open in blu 3 wire circuit to TB10 5 48 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 5 Troubleshooting Flow Charts Disconnect the blu 1 1 wire to the secondary boom down directional valve coil Test the resistance of the valve Continued from the previous page coil See Repair Section Exchange the secondary and primary boom down directional valves items AJ and Al or BJ and Bl or CU and CT Activate the secondary boom UP function Install a 0 to 5000 PSI 0 to 345 bar pressure gauge at the quick disconnect coupling on the function manifold 2 34 22 before serial number 153 and Z34 22N before serial number 304 Move the secondary boom toggle Switch in the DOWN direction and check the pressure 2 34 22 after serial number 153 and Z 34 22N after serial number 304 Hold the function enable toggle switch to either side and move the secondary boom toggle switch in the DOWN direction and check the pressure 3200 PSI Check for mechanical restrictions keeping the secondary boom down function from operating OR repair cylinder s or cylinder s counterbalance valve s OR consult Genie Industries Service Department function inoperative CHART 12 Replace the secondary boom down directional valve coil Replace defective directional valve Adjust the system relief valve see Repair
322. om TB12 to terminal A on the joystick controller Repair open in blu wht wire from TB12 to pin 2 on the motor controller harness connector Check voltage on the 48V org red wire at PR1 oV Repair open in org red wire circuit from TB42 to PRI Install a new diode onto with the band on the diode aligned with the red 27 wire CHART 29C Replace PR1 Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 5 115 Section 5 Troubleshooting Flow Charts First Edition Third Printing CHART 29C Check voltage between the terminals B and B on the motor controller Note the voltage Press down the foot switch and check voltage between pin 1 on the motor controller harness connector and terminal B Is the voltage within 1V of the first reading Continued from the previous page Repair open in grn wire from PR1 to pin 17 OR replace PR1 OR test the motor controller See Repair Section Drive function should be operating normally If it does not begin troubleshooting from beginning of chart Disconnect the batteries from the machine Remove the PR1 mounting fasteners Clean all 4 contact tips until they are clean and smooth Install the contactor onto the power panel and connect the batteries Turn key switch to platform controls and pull both Emergency Stop buttons out to the ON position Press down the foot switch and test the drive function Does the machine driv
323. om the primary boom cable track to the platform control box Number each cable and its entry location at the platform control box 6 Openthe platform control box 7 Label and disconnect each wire of the 4 cables in the platform control box AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 8 Pull all of the cables out of the platform control box 9 Tag disconnect and plug the hydraulic hoses from the slave 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 10 Tag disconnect and plug the hydraulic hoses from the jib rotate manifold AWARNING 2odily 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 11 Remove the upper cable track mounting fasteners from the platform end of the boom 7 20 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 7 Repair Procedures 12 Remove the cable track mounting fasteners then remove the cable track from the boom and lay it flat on the ground Component damage hazard CAUTION Cables and hoses can
324. on proportional valve coil item AU or BU or CH Z 34 22 after serial number 1733 and Z 34 22N after serial number 2226 Hold the function enable toggle Switch to either side and move the secondary boom toggle switch TS60 in the UP direction and check voltage on the wht red 6 wire at the boom function proportional valve coil item AU or BU or CH 24N Continued on page 44 2 34 22 before serial number 153 and Z34 22N before serial number 304 Move the 24V secondary boom toggle switch in the DOWN direction and check voltage at TB6 Z 34 22 after serial number 152 and 234 22 after serial number 303 Hold the function enable toggle switch to either side and move the secondary boom toggle switch in the DOWN direction and check voltage at TB6 Turn key switch to 24V platform controls and pull both Emergency Stop buttons out to the ON position With the boom function speed controller turned to 9 press down the foot switch and move the secondary boom toggle switch Z 34 22 before serial number 1734 and Z 34 22N before serial number 2227 TS2 Z 34 22 after serial number 1733 and Z 34 22N after serial number 2226 TS10 in the uP direction Check voltage at blk red at boom function speed controller ov Continued on the next page Repair open in wht red wire circuit from TB6 to boom function proportional valve coil OR repair open in brn ground wire circuit from the boom function pro
325. onal valve coil OR repair open in brn ground wire circuit to boom function proportional valve coil 24V Repair open in blk red to wht red wire circuit to TB6 5 46 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 5 Troubleshooting Flow Charts CHART 12 Press down the foot Repair open in wht red switch and move the wire circuit through secondary boom toggle boom function toggle switch in the DOWN switches to the red wire direction Check the on the boom function voltage at the red wire speed controller on the boom function speed controller Continued from the previous page Press down the foot Repair open in ground switch and move the wire circuit from the secondary boom toggle boom function speed switch in the DOWN controller to ground OR direction Check voltage replace the boom at the blk red wire on the function speed boom function speed controller controller Repair open in blk red wire from the boom function speed controller to TB6 Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 5 47 Section 5 Troubleshooting Flow Charts CHART 12 Continued from page 46 2 34 22 before serial number 153 and Z34 22N before serial number 304 Move the secondary boom toggle switch in the UP direction and check voltage on t
326. ons listed below to check for continuity Center Right Single pole double throw SPDT GLa 21910 01019 21210 Double pole double throw DPDT Test Left position Desired result terminal 1 to 2 3 4 5 amp 6 no continuity infinite terminal 2 to 3 continuity zero Q terminal 2 to 4 5 amp 6 no continuity infinite Q terminal 3 to 4 5 amp 6 no continuity infinite Q terminal 4 to 5 amp 6 no continuity infinite Q terminal 5 to 6 Center position continuity zero Q There are no terminal combinations that will produce continuity infinite Q Right position terminal 1 to 2 continuity zero Q terminal 1 to 3 4 5 amp 6 no continuity infinite terminal 2 to 3 4 5 amp 6 no continuity infinite Q terminal 3 to 4 5 amp 6 no continuity infinite terminal 4 to 5 continuity zero Q terminal 4 to 6 no continuity infinite Q terminal 5 to 6 no continuity infinite Q 7 10 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 7 Repair Procedures Platform Components 2 1 Platform How to Remove the Platform 1 Separate the foot switch wiring quick disconnect plug from the platform toeboard 2 Remove the platform control box mounting fasteners then lower the control box If your machine is equipped with an
327. ons operate normally Be sure key switch is in the appropriate position Be sure the Emergency Stop buttons are pulled out to the oN position Be sure the battery packs are properly connected and fully charged Turn key switch to ground controls and pull both Emergency Stop buttons out to the ON position Lift the red auxiliary pump switch cover and hold the auxiliary toggle switch Z 34 22 before serial number 1734 and Z 34 22N before serial number 2227 TS17 Z 34 22 after serial number 1733 and Z 34 22N after serial number 2226 TS51 in the ON direction Move any boom function toggle switch and listen for the sound of the auxiliary pump motor operating motor does not operate Hold the auxiliary pump toggle switch and move any boom function toggle switch Check voltage at the red cable on the auxiliary power unit ov Continued on the next page motor operates 24V Chart 3 Install a 010 5000 psi 0 to 345 bar pressure gauge into the pressure port of the auxiliary pump and hold the Immediately stop The pump is good There is possibly not enough 2800 psi battery capacity to operate both the auxiliary pump and auxiliary power toggle function valves switch and move any boom function toggle switch Note the pressure less than 2800 psi Repair or replace the Check for a positive pump OR consult the connection between the good electric mo
328. operate The drive controller joystick is fitted with a potentiometer that communicates the drive controller position with the motor controller A thumb rocker switch on the top of the drive controller is used for steering Washing electronic components is not suggested Instead use compressed air to remove debris Component damage hazard Avoid ACAUTION shock or impact to the motor controller Internal damage may not be visible from the outside vi Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Introduction Section One Section Two Section Three Section Four Table of Contents Important Informmationh reiner eee tct eerte tee tees ii Safety Rules General Safety Rules sssssssssssssessesesesee eene ener nennen nennen ennt ennt nennen iii Theoryof Operation REDE EEG Specifications Machine Specifications essssssssssseseseeeen eene nennen nennen nnne 2 1 Performance Specifications nnns 2 2 Hydraulic Specifications esssssssssssssssseeeeneeenene enne 2 3 Hydraulic Hose and Fitting Torque Specifications 2 4 SAE and Metric Fastener Torque Chart 2 5 Scheduled Maintenance Inspections Introduction 3 1
329. operating OR repair cylinder or cylinder counterbalance valve OR consult Genie Industries Service Department Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 5 59 Section 5 Troubleshooting Flow Charts First Edition Third Printing Chart 15 Turntable Rotate Left Function inoperative Be sure key switch is in the appropriate position Be sure the Emergency Stop buttons are pulled up to the on position Be sure the battery packs are properly connected and fully charged Turn key switch to ground controls and pull both Emergency Stop buttons out to the ON position 2 34 22 before serial number 153 and Z34 22N before serial number 304 Move the turntable rotate toggle switch TS10 in the LEFT direction and check voltage on the wht red 6 wire at the boom function proportional valve coil item AU Z 34 22 from serial number 153 to 1733 and Z 34 22N from serial number 304 to 2226 Hold the function enable toggle switch to either side and move the turntable rotate toggle switch TS10 in the LEFT direction and check voltage on the wht red 6 wire at the boom function proportional valve coil item AU or BU Z 34 22 after serial number 1733 and Z 34 22N after serial number 2226 Hold the function enable toggle switch to either side and move the turntable rotate toggle switch TS62 in the LEFT direction and check voltage on the wht red 6 wire at the boom function proportional valve coil i
330. or Z 34 22 from serial number 153 to 1733 and Z 34 22N from serial number 304 to 2226 Hold the function enable toggle switch to either side and move the primary boom toggle Switch TS12 in the UP direction and check voltage on the wht red 6 wire at the boom function proportional valve coil item AU or BU or CH Z 34 22 after serial number 1733 and Z 34 22N after serial number 2226 Hold the function enable toggle switch to either side and move the primary boom toggle switch TS61 in the UP direction and check voltage on the wht red 6 wire at the boom function proportional valve coil item AU or BU or CH 24V Continued on page 36 2 34 22 before serial number 153 and 234 22 before serial number 304 Move the primary boom toggle 24V switch in the UP direction and check voltage at TB6 2 34 22 after serial number 152 and 234 22 after serial number 303 Hold the function enable toggle switch to either side and move the primary boom toggle switch in the up direction and check voltage at TB6 ov Turn key switch to platform controls and pull both Emergency Stop buttons out to the ON position With the boom function speed controller turned to 9 press down the foot switch and move the primary boom toggle switch 2 34 22 before serial number 1734 and Z 34 22N before serial number 2227 TS3 Z 34 22 after serial number 1733 and Z 34 22N after serial number 2226 TS11 in the UP dire
331. orm controls and pull both Emergency Stop buttons out to the ON position With the boom function speed controller turned to 9 press down the foot switch and move the platform level toggle switch 2 34 22 before serial number 1734 and Z 34 22N before serial number 2227 TS5 2 34 22 after serial number 1733 and Z 34 22N after serial number 2226 59 in the UP direction Check voltage at TP6 24V Continued on the next page Chart 18 Repair open in wht red 6 wire circuit from TB6 to the boom function proportional valve coil OR repair open in the ground wire circuit to the boom function proportional valve coil Repair open in wht red wire circuit from TP6 to to TB6 Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 5 71 Section 5 Troubleshooting Flow Charts CHART 18 Continued from the previous page Press down the foot switch and move the platform level toggle switch in the UP direction Check the voltage at the red wire on the boom function speed controller Press down the foot switch and move the platform level toggle switch in the uP direction Check the voltage at the blk red wire on the boom function speed controller Repair open in blk red wire from the boom function speed controller to TB6 First Edition Third Printing Repair open in grn wht
332. ormance Failure to find and replace burnt chafed corroded or pinched wires could result in unsafe operating conditions and may cause component damage Electrocution burn hazard Contact AWARNING with hot or live circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Inspect the following areas for burnt chafed corroded and loose wires Electrical power panel Electrical relay panel e Ground control panel Turntable manifold wiring 2 Turn the key switch to ground control and pull out the Emergency Stop button to the oN position 3 Raise the secondary boom until the lower mid pivot is approximately 10 feet 3 m off the ground 4 Inspect the turntable center area for burnt chafed and pinched cables TABLE B PROCEDURES 5 Lowerthe boom to the stowed position and turn the machine off 6 Inspect the following areas for burnt chafed corroded pinched and loose wires Cable track on the primary boom Primary boom to platform cable harness Inside of the platform control box Part No 36540 Genie Z 34 22 amp Genie Z 34 22N Section 4 Scheduled Maintenance Procedures First Edition Third Printing TABLE B PROCEDURES B 3 Inspect the Tires and Wheels including lug nut torque Maintaining the tires and wheels in good condition is essential to safe operation and good performance Tire and or wheel failure could result in a machine tip over Compon
333. ov Repare or replace drive controller OR consult Genie Industries Service Department Replace brake release valve coil CHART 28A Repair open in red wht wire circuit from TB29 to the brake release valve Repair open in red wht wire with diode from 1 2 stroke micro switch on drive controller to TB29 Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 5 107 Section 5 Troubleshooting Flow Charts First Edition Third Printing CHART 28 Continued from the previous page Press down the foot Repair open in red 47 switch and move the wire circuit from TB47 to drive controller in the pressure switch to brake FORWARD direction until release valve N C OR the 1 2 stroke micro repair open in ground switch activates Check wire circuit from brake voltage at red wire on release valve N C coil brake release valve N C to ground item L 20V or more the wires bitis rom the brake release valve NC coil Test ihi ohms Replace brake release valve N C coil resistance of the valve coil See Repair Section 22 to 24 ohms Connect an ammeter in Disconnect the wires 18 to 20 Adjust drive controller series with wht red wire from the brake ohms See Repair Section and brake proportional proportional valve coil OR repair open in wht valve
334. ove the wire circuit from the platform rotate toggle boom function speed switch in the LEFT controller to ground OR direction Check voltage replace the boom at the blk red wire on the function speed boom function speed controller controller Repair open in blk red wire from the boom function speed controller to TB6 Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 5 81 Section 5 Troubleshooting Flow Charts CHART 20 Continued from page 80 Turn key switch to ground controls and pull both Emergency Stop buttons out to the position Z 34 22 before serial number 153 and Z34 22N before serial number 304 Move platform rotate toggle switch in the LEFT direction and check voltage on the grn wire on the platform rotate left directional valve coil item D Z 34 22 after serial number 152 and Z34 22N after serial number 303 Hold the function enable toggle switch to either side and move the platform rotate toggle switch in the LEFT direction and check voltage on the grn wire on the platform rotate left directional valve coil item D 24N Continued on the next page First Edition Third Printing Z 34 22 before serial number 153 and Z34 22N before serial 24V number 304 Move the platform rotate toggle switch in the LEFT direction and check voltage at TB17 Z 34 22 after serial number 152 and Z34 22N after serial number 303 Hold the function enable toggle switch to either s
335. p Genie Z 34 22N Part No 36540 First Edition Third Printing Section 7 Repair Procedures 5 1 Secondary Boom How to Disassemble the Secondary Boom AWARNING injury hazard The procedures in this section require 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 required Follow the disassembly steps to the point required to complete the repair Then re assemble the secondary boom by following the disassembly steps in reverse order When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Lower the boom to the stowed position 2 Place a lifting device under the front of the platform Remove the rear turntable cover A Remove the cable cover from the side of the jib boom SECONDARY BOOM COMPONENTS 5 Remove the wire loom from the cables at the platform control box 6 Locate the 4 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 Label and disconnect each wire of the 4 cables in the platform control box AWARNING Electrocut
336. p Genie Z 34 22N 6 42 First Edition Third Printing Section 6 Schematics EEE IMR Hydraulic Schematic Z 34 22 from serial number 674 to 1733 Z 34 22N from serial number 935 to 2226 Section 6 Schematics First Edition Third Printing Hydraulic Schematic 7 34 22 from serial number 1734 to 2005 Z 34 22N from serial number 2227 to 2771 A B C D E F G H J K L M 1 JIB BOOM PLATFORM CYLINDER ROTATE E E ME 3000 PSI DOWN V1 3000 PSI V2 207 bar 207 bar JIB UP DOWN 3 PLATFORM ROTATE J1 J2 PRI PR2 MANIFOLD PLATFORM LEVEL 2 0 025 inch 0 64 mm 1 3 SLAVE CYLINDER before serial number 234 1982 and Z34N 2548 dan Oe MR 892 to 2005 and Z34N 2548 to 2771 m l
337. p buttons are pulled out to the on position Be sure the battery packs are properly connected and fully charged ON position Press down the foot switch and move the drive controller in the REVERSE direction and check voltage on wht 30 wire on forward reverse contactor PR2 Press down the foot switch and move the drive controller in the REVERSE direction and check voltage on TB30 Press down the foot switch and move the drive controller in the REVERSE direction and check voltage on wht 1 wire on micro switch on the drive controller Repair or replace micro switch on the drive controller OR drive controller cams are out of adjustment Consult Genie Industries Service Department 40 ohms Repair or replace PR2 contacts OR repair open in ground wire circuit OR consult Genie Industries Service Department Repair open in wht 30 wire circuit from TB30 to forward reverse contactor Repair open in wire circuit from wht 1 wire on micro switch on the drive controller to TB31 Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 5 121 Section 5 Troubleshooting Flow Charts First Edition Third Printing Chart 33 Machine Will Not Drive At Full Speed Z 34 22 before serial number 1734 and Z 34 22N before serial number 2227 Be sure the unit is in the fully stowed position with the boom located between the non steer end tires Be sure the battery packs are properl
338. packs Repair open in power wire from 100A fuse F3 to PR4 to CB1 Reset or replace circuit breaker CB1 OR consult Genie Industries Service Department Repair open in red wire from CB1 to the Emergency Stop button Chart 1 Part No 36540 Genie Z 34 22 amp Genie Z 34 22N Section 5 Troubleshooting Flow Charts First Edition Third Printing CHART 1 Check voltage at the output side of the Emergency Stop button Continued from the previous page Check voltage at the input side of the key switch Turn key switch to ground controls and check voltage on output side of ground controls contact of the keyswitch Continued on the next page Check to see if Emergency Stop button contact is being activated Replace Emergency Stop button contact Replace Emergency Stop button OR refer to Ground Controls Inoperative Chart 6 OR consult Genie Industries Service Department Repair open in red wire from Emergency Stop button to key switch Check to see if key Replace key switch switch internal cam is contact for ground activating ground controls controls contact Replace key switch OR refer to Ground Controls Inoperative Chart 6 OR consult Genie Industries Service Department 5 8 Genie 2 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 5 Troubleshooting Flow Charts Continued from the previous page
339. page less than 2800 psi Test master cylinder OR repair or replace slave cylinder or slave cylinder counterbalance valves OR boom function manifold could have an internal defect Consult Genie Industries Service Department Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 5 75 Section 5 Troubleshooting Flow Charts First Edition Third Printing Chart 19 Platform Level Down Function inoperative Be sure key switch is in the appropriate position Be sure the Emergency Stop buttons are pulled out to the on position Be sure the battery packs are properly connected and fully charged Turn key switch to ground controls and pull both Emergency Stop buttons out to the on position 2 34 22 before serial number 153 and Z34 22N before serial number 304 Move the platform level toggle Switch TS14 in the DOWN direction and check the voltage on the wht red 6 wire at the boom function proportional valve coil item AU 2 34 22 from serial number 153 to 1733 and Z 34 22N from serial number 304 to 2226 Hold the function enable toggle switch to either side and move the platform level toggle Switch TS14 in the DOWN direction and check the voltage on the wht red 6 wire at the boom function proportional valve coil item AU or BU Z 34 22 after serial number 1733 and Z 34 22N after serial number 2226 Hold the function enable toggle switch to either side and move the platform level tog
340. pair open in red 20 wire circuit from PR4 to terminal 9 on CR8 Z 34 22 after serial number 1733 and Z 34 22N after serial number 2226 Repair open in red wire circuit from the key switch ground controls contact to the function enable switch to terminal 30 on CR3 5 14 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 5 Troubleshooting Flow Charts CHART 2 2 34 22 before serial 2 34 22 from serial Continued from the number 153 and number 153 to 1733 previous page Z 34 22N before serial and Z 34 22N from number 304 Replace serial number 304 to CR2 2226 Repair open in Z 34 22 from serial ground wire circuit from number 153 to 1733 terminal 14 on CR8 to and Z 34 22N from ground OR replace CR8 serial number 304 to OR replace the relay 2226 Hold the function socket enable switch to either Z 34 22 after serial side and move the number 1733 and primary boom extend Z 34 22N after serial retract toggle switch in number 2226 Repair the RETRACT direction open in ground wire and check voltage at circuit with diode from terminal 13 on CR8 terminal 86 on CR20 to Z 34 22 after serial ground OR replace number 1733 and diode OR replace CR20 Z 34 22N after serial OR replace the relay number 2226 Hold the socket function enable switch to either side and move the primary boom extend retract toggle switch in the RETRACT direction and check voltage at ter
341. pen in wht wire from terminal 6 on the drive controller to the center terminal on TS15 Replace the drive enable toggle switch OR repair open in the wht wire from TS15 to center terminal 51 38 36540 Genie Z 34 22 amp Genie Z 34 22N 5 129 Section 5 Troubleshooting Flow Charts First Edition Third Printing Chart 39 Remote Brake Release Inoperative 234 22 before serial number 3578 and Z34 22N before serial number 4261 Be sure all other functions operate normally Be sure the battery packs are properly connected and fully charged Pull the Emergency Stop button at ground controls out to the ON position Check voltage at the input side of the remote brake release jack J1 on the ground control panel With the remote brake release switch plugged into the remote brake release jack on the ground control panel press down the remote brake release button and check voltage at the output side of the plug 2 34 22 before serial number 1734 and Z 34 22N before serial number 2227 Activate remote brake release and check voltage at TB46 2 34 22 after serial number 1733 and Z 34 22N after serial number 2226 Activate remote brake release and check voltage at TB48 2 34 22 before serial number 1734 and Z 34 22N before serial number 2227 Activate remote brake release and check voltage at TB47 Remote brake release func
342. pivot pin Do not remove the pin Part No 36540 Genie Z 34 22 amp Genie Z 34 22N Section 7 Repair Procedures First Edition Third Printing r M i Jas i PLATFORM COMPONENTS 4 Remove the external snap ring from the How to Bleed the Slave Cylinder barrel end pivot pin 5 Place a block of wood under the barrel end of 1 Raisethe jib boom to a horizontal position the slave cylinder 2 Move the platform level toggle switch up and 6 Use a soft metal drift to remove the rod end down through two platform leveling cycles to pivot pin remove any air that might be in the system 7 Use a soft metal drift to remove the barrel end pivot pin 8 Carefully pull the cylinder out of the boom AWARNING Crushing hazard The slave cylinder will fall unless it is properly supported 9 Tag and disconnect the hydraulic hoses from the slave cylinder and connect them together with a connector 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 7 12 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 7 Repair Procedures 2 3 Platform Rotator The platform rotator is a hydraulically activated helical gear assembly used
343. portional valve coil item AU Z 34 22 from serial number 153 to 1733 and Z 34 22N from serial number 304 to 2226 Hold the function enable toggle switch to either side and move the turntable rotate toggle switch TS10 in the RIGHT direction and check voltage on the wht red 6 wire at the boom function proportional valve coil item AU or BU Z 34 22 after serial number 1733 and Z 34 22N after serial number 2226 Hold the function enable toggle switch to either side and move the turntable rotate toggle switch TS62 in the RIGHT direction and check voltage on the wht red 6 wire at the boom function proportional valve coil item CH 24N Continued on page 67 2 34 22 before serial number 153 and Z34 22N before serial number 304 Move the 24V turntable rotate toggle Switch in the RIGHT direction and check the voltage at TB6 2 34 22 after serial number 152 and Z34 22N after serial number 303 Hold the function enable toggle Switch to either side and move the turntable rotate toggle switch in the RIGHT direction and check the voltage at TB6 Turn key switch to 24V platform controls and pull both Emergency Stop buttons out to the ON position With the boom function speed controller turned to 9 press down the foot switch and move the turntable rotate toggle switch Z 34 22 before serial number 1734 and Z 34 22N before serial number 2227 TS1 Z 34 22 after serial number 1733 and Z 34 22N after se
344. portional valve coil to ground Repair open in blk red to wht red wire circuit to TB6 5 42 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 5 Troubleshooting Flow Charts 11 Press down the foot Repair open in wht red switch and move the wire circuit through secondary boom toggle boom function toggle switch in the UP switches to the red wire direction Check voltage on the boom function at the red wire on the speed controller boom function speed controller Continued from the previous page Press down the foot Repair open in grn wire switch and move the from the boom function secondary boom toggle speed controller to switch in the uP ground OR replace the direction Check voltage boom function speed at the blk red wire on the controller boom function speed controller Repair open in blk red wire circuit from the boom function speed controller to TB6 Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 5 43 Section 5 Troubleshooting Flow Charts First Edition Third Printing CHART 11 2 34 22 before serial number 153 and Z34 22N before serial number 304 Move the secondary boom toggle switch in the UP direction and check voltage on the blu 10 wire on the secondary boom up directional valve coil item E 2 34 22 from serial number 153 to 1733 and Z 34 22N from serial number 304 to 2226 Hold the func
345. properly supported Support and slide the extension tube out of the primary boom tube Place the extension tube on blocks for support During removal the overhead crane strap will need to be carefully adjusted for proper balancing Remove the retaining 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 Support and slide the extension cylinder out of the pivot end of the boom extension tube Place the extension cylinder on blocks for support During removal the overhead crane strap will need to be carefully adjusted for proper balancing 10 Remove and label the wear pads from the extension cylinder Pay careful attention to the location of each wear pad 7 22 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 7 Repair Procedures 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 counterbalance valves to prevent movement in the event of a hydraulic line failure How to Remove the Primary Boom Lift Cylinder AWARNING Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is stro
346. ption e Overload light option Power switch PR Power relay Pressure switch TB q e Terminal base location Terminal platform location TO Toggle switch Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 6 9 Section 6 Schematics First Edition Third Printing EEUU eee LLL E LL e LL LLLI Electrical Symbols Legend PES T817 2H 8 EN x Horn Alarm Wire color S Drive controller with cable TN Joystick number 1820 Ground Flashi p RED GAN lt supression pen p Solenoid or beacon E A circuit 5 relay E a Terminal Lan fs Circuit breaker Boom function j speed controller FORWARD REVERSE He ef Pere ay meter Relay contact Quick disconnect i normally open terminal Dual pole power relay J1 Limit switch 21 BLK 21 ry CR4 T circuits connect Brake release la at terminal jack Relay contact normally closed Power relay normally open iren Motor controller before id T circuits am fehl 234 1737 Z34N 2227 88 Fuse NOHC BE Toggle switch SPDT NE 7 000 Limit switch BU normally open Connection cdl held closed K itch no terminal Ai S1 186 ey switc before 734 3578 Drive motor and Z34N 4261 s
347. r 2871 04260 6 21 Electrical Schematic Z 34 22 from serial number 3578 to 4799 and Z 34 22N from serial number 4261 5619 6 23 Electrical Schematic Z 34 22 after serial number 4799 and Z 34 22N 5619 22222 6 25 Electrical Schematic CE Models Z 34 22 after serial number 4799 and Z 34 22N after serial number 5619 022 2 2022 4 0 0 6 27 Xiv Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing EET Section Six Schematics continued Ground Control Panel Legend Z 34 22 before serial number 153 and Z 34 22N before serial 04 Ground Control Panel Wiring Diagram Z 34 22 from serial number 153 to 1733 and Z 34 22N from serial number 304 to 2226 Ground Control Panel Wiring Diagram Z 34 22 from serial number 1734 to 1999 and Z 34 22N from serial number 2227 to 2750 Ground Control Panel Wiring Diagram Z 34 22 from serial number 2000 to 3577 and Z 34 22N from serial number 2751 to 4260 Ground Control Panel Wiring Diagram Z 34 22 from serial number 3578 to 4799 and Z 34 22N from serial number 4261 to 5619 Ground Control Panel Wiring Diagram Z 34 22 after serial numb
348. r cylinder rod end oqqq pa master cylinder and hydraulic hose hose raise the primary boom connected to port C1 one inch 2 5 cm ata using a tee fitting Move time Continually the primary boom toggle monitor the pressure switch in the uP direction gauge while raising the and check the pressure primary boom Do not Z 34 22 after serial allow the pressure to number 152 and exceed 2500 PSI Z34 22N after serial number 303 Plumb a 0 to 5000 psi 0 to 345 bar pressure gauge into master cylinder rod end hydraulic hose Z 34 22 before serial number 1734 and Z 34 22N before serial number 2227 hose connected to port C1 2 34 22 after serial number 1733 and Z 34 22N after serial number 2226 hose connected to port L1 using a tee fitting Hold the function enable switch to either side and move the primary boom toggle switch in the UP direction and check the pressure 2000 PSI or more Repair or replace the slave cylinder 2000 PSI Check for mechanical restrictions keeping the platform level function from operating OR replace the slave cylinder counterbalance valves 5 70 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 5 Troubleshooting Flow Charts Platform Level Up Function Inoperative Be sure key switch is in the appropriate position Be sure the Emergency Stop buttons are pulled out to the oN position Be sure the battery packs ar
349. r malfunction before operating the machine Before Repairs Start Read understand and obey the safety rules and operating instructions in the Genie Z 34 22 amp Genie Z 34 22N Operator s Manual Be sure that all necessary tools and parts available and ready for use Read each procedure completely and adhere to the instructions Attempting shortcuts may produce hazardous conditions Unless otherwise specified perform each repair procedure with the machine in the following configuration Machine parked on a flat level surface Boom in stowed position Turntable rotated with the boom between the non steering wheels Key switch in the orr position with the key removed Wheels chocked Repair Procedures About This Section Most of the procedures in this section should only be performed by a 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 r7 Red used to indicate the A DANGER presence of an imminently hazardous situation which if not avoided will result in death
350. r of the platform during rotation clear hose top bleed valve bottom bleed valve container 7 14 Genie 7 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 7 Repair Procedures m M a HM Hc T s nM PLATFORM COMPONENTS Z 34 22 before serial number 153 and Z 34 22N before serial number 304 Move the platform rotate toggle switch to the left for approximately 5 seconds then release it Repeat three times Z 34 22 after serial number 152 and Z 34 22N after serial number 303 Hold the function enable switch to either side and move the platform rotate toggle switch to the left for approximately 5 seconds then release it Repeat three times 6 Fully rotate the platform to the left and continue holding the platform rotate toggle switch until air stops coming out of the bleed valve Immediately release the platform rotate toggle switch and close the bleed valve 7 Rotate the platform to the right until the platform is centered 8 Connect the clear hose to the bottom bleed valve and open the valve Do not remove the valve 9 Move the platform rotate toggle switch to the right and continue holding the platform rotate toggle switch until air stops coming out of the bleed valve AWARNING Crushing hazard Keep clear of the platform during rotation 10 Close the bleed valve and remove the hose 11 Rotat
351. r s number 152 and counterbalance valve s Z34 22N after serial OR function manifold number 303 Hold the could have an internal function enable toggle defect Consult Genie Switch to either side and Industries Service move the secondary Department boom toggle switch in the UP direction and check the pressure 3200 PSI Check for mechanical restrictions keeping the secondary boom up function from operating OR repair cylinder s or cylinder s counterbalance valve s OR consult Genie Industries Service Department Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 5 45 Section 5 Troubleshooting Flow Charts First Edition Third Printing Chart 12 Secondary Boom Down Function inoperative Be sure key switch is in the appropriate position Be sure the Emergency Stop buttons are pulled out to the on position Be sure the battery packs are properly connected and fully charged Turn key switch to ground controls and pull both Emergency Stop buttons out to the ON position 2 34 22 before serial number 153 and Z34 22N before serial number 304 Move the secondary boom toggle switch TS11 in the DOWN direction and check voltage on the wht red 6 wire at the boom function proportional valve coil item AU or BU or Z 34 22 from serial number 153 to 1733 and Z 34 22N from serial number 304 to 2226 Hold the function enable toggle switch to either side and move the secondary boom toggle switch TS11
352. ract toggle switch Z 34 22 before serial number 1734 and Z 34 22N before serial number 2227 TS4 Z 34 22 after serial number 1733 and Z 34 22N after serial number 2226 TS13 in the EXTEND direction Check voltage at TP6 ov Continued on the next page Chart 14 Repair open in wht red 6 wire circuit from TB6 to the boom function proportional valve coil OR repair open in the ground wire circuit to the boom function proportional valve coil Repair open in blk red wire circuit from TP6 to to TB6 Part No 36540 Genie Z 34 22 amp Genie Z 34 22N Section 5 Troubleshooting Flow Charts CHART 14 Continued from the previous page Press down the foot switch and move the primary boom extend retract toggle switch in the RETRACT direction Check voltage at the red wire on the boom function speed controller Press down the foot switch and move the primary boom extend retract toggle switch in the RETRACT direction Check voltage at the blk red wire on the boom function speed controller Repair open in blk red wire from the boom function speed controller to TB6 First Edition Third Printing Repair open in wht red wire circuit through boom function toggle switches to the red wire on the boom function speed controller Repa
353. rcuit from TB7 to primary boom extend directional valve coil OR repair open in brn ground wire circuit to manifold 24V Troubleshoot the primary boom extend retract toggle switch on ground controls OR replace diode on toggle switch OR repair open in blk 7 wire circuit from toggle switch to TB7 OR replace toggle switch 552 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 5 Troubleshooting Flow Charts 13 0 or infinite ohms Disconnect the blk wire to the primary boom Replace the primary extend directional valve boom extend directional coil Test the resistance valve coil of the valve coil See Repair Section Continued from the previous page function operates Exchange the primary boom extend and retract directional valves items AT and AC or BT and BC or CK and CU Activate the primary boom EXTEND function Replace defective directional valve function inoperative Continued on the next page Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 5 53 Section 5 Troubleshooting Flow Charts First Edition Third Printing EEE NSN CHART 13 Install 0 to 5000 PSI 0 Adjust the system relief to 345 bar pressure valve see Repair gauge at the quick Section item AB or BB disconnect coupling on or CR OR repair or the function manifold less than replace cylinder s or
354. rd Printing JIB BOOM COMPONENTS 3 3 Jib Boom Lift Cylinder How to Remove the Jib Boom Lift Cylinder Perform this procedure with the boom in the stowed position When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Raise the jib boom slightly and place blocks under the platform mounting weldment Lower the jib boom until the platform is resting on the blocks 11 Ld e ea E 2 Tag disconnect and plug the jib boom lift cylinder hydraulic hoses Cap the fittings on the jib boom lift 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 Remove the pin retaining fasteners from the jib boom lift cylinder rod end pivot pin Do not remove the pin 4 Use a soft metal drift to tap the rod end pivot pin half way out and lower one of the leveling links to the ground Tap the pin the other direction and lower the opposite leveling link Do not remove the pin 5 Attach a lifting strap from an overhead crane to the rod end of the jib boom lift cylinder 6 Remove the pin retaining fasteners from the jib boom lift cylinder barrel end
355. re switch Repair open in org blk wire circuit with diode from TB41 to TB47 OR replace diode Repair open in org blk wire circuit from terminal X on the drive controller to TB41 Repair open in power circuit from drive enable toggle switch TS9 to TB12 to LS3 to TB16 to terminal on drive controller OR replace LS3 OR consult Genie Industries Service Department 5 106 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Continued from the previous page Press down the foot Switch and move the drive controller in the FORWARD direction until the 1 2 stroke micro Switch activates and check voltage at red wht and ground wires on 1 2 stroke brake release valve item H 20V or more 0 or infinite ohms Disconnect red wht 29 and ground wires from 1 2 stroke brake release valve coil Test the resistance of the valve coil See Repair Section 22 to 24 ohms Continued on the next page Section 5 Troubleshooting Flow Charts SS 20V or Press down the foot more switch and move the drive controller in the FORWARD direction until the 1 2 stroke micro switch activates and check voltage at TB29 Press down the foot 20V or switch and move the more drive controller in the FORWARD direction until the 1 2 stroke micro switch activates and check voltage at red wht wire on 1 2 stroke micro switch on drive controller
356. red auxiliary power switch cover Simultaneously hold the auxiliary power Switch while activating each function through a partial cycle should operate smoothly Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 4 7 Section 4 Scheduled Maintenance Procedures First Edition Third Printing TABLE A PROCEDURES A 8 Test the Tilt Sensor The tilt sensor sounds an alarm in the platform when the incline of the machine exceeds the rating on the serial plate Select a level test area The tilt alarm should not be sounding prior to test 1 Turn the key switch to platform control and pull out the Emergency Stop button to the position at both the ground and platform controls 2 Open the ground control side turntable cover and press down on one side of the tilt sensor Hold for 5 seconds Result The alarm located in the platform should sound Tip over hazard The alarm should AWRRNING be heard at the ground controls If you can t hear the alarm at the ground controls replace the alarm in the platform A 9 Test the Limit Switches Detecting limit switch malfunctions is essential to safe machine operation The drive limit switch is used to restrict drive speed when the boom is raised or extended The drive enable limit switch activates a signal light to inform the operator that the platform is over the steering wheels and stops drive movement unless the drive enable override Switch is used I
357. rial number 2226 512 in the RIGHT direction Check voltage at TP6 ov Continued on the next page Chart 16 Repair open in wht red 6 wire circuit from TB6 to the boom function proportional valve coil OR repair open in the ground wire circuit to the boom function proportional valve coil Repair open in blk red wire circuit from TP6 to to TB6 Part No 36540 Genie 7 34 22 amp Genie Z 34 22N Section 5 Troubleshooting Flow Charts EEE CHART 16 Continued from the previous page Press down the foot switch and move the turntable rotate toggle switch in the RIGHT direction Check the voltage at the red wire on the boom function speed controller Press down the foot switch and move the turntable rotate function toggle switch in the RIGHT direction Check the voltage at the blk red wire on the boom function speed controller Repair open in blk red wire from the boom function speed controller to TB6 First Edition Third Printing Repair open in red wht wire circuit through boom function toggle switches to the red wire on the boom function speed controller Repair open in ground wire circuit from the boom function speed controller to ground OR replace the boom function speed controller Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 5 Troubleshooting Flow Charts CHART 16 Continued from pag
358. rive At Full Speed Z 34 22 after serial number 1733 and Z 34 22N after serial number 2226 5 123 Machine Drives At Full Speed With Platform Raised Or Extended Z 34 22 before serial number 1734 and Z 34 22N before serial number 2227 sss 5 125 Machine Drives At Full Speed With Platform Raised Or Extended Z 34 22 after serial number 1733 and Z 34 22N after serial number 2226 sse 5 126 Drive Enable System Is Malfunctioning Z 34 22 before serial number 1734 and Z 34 22N before 2227 5 127 Drive Enable System Is Malfunctioning Z 34 22 after serial number 1733 and Z 34 22N after serial number 2226 sese 5 129 Remote Brake Release Inoperative Z 34 22 before serial number 3578 and Z 34 22N before serial number 4261 5 130 Xii Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Es Section Six TABLE OF CONTENTS Schematics nifoielB eile p 6 1 Electrical Components th ettet Eee iden 6 2 Load Sensor Option Diagram Z 34 22 before serial number 1734 and Z 34 22N before 2227 6 4 Load Sensor Option Diagram Z 34 22 from serial number 1734 to 2060 and Z 34 22N from serial number 2227 to 2870
359. rom the jib down directional valve coil Test the resistance of the valve coil See Repair Section Continued from the previous page Replace jib down directional valve coil Exchange the jib up and_ function jib down directional operates valves item A and Activate the jib down function Replace defective directional valve function inoperative Install a 0 to 3000 PSI Check for mechanical 0 to 207 bar pressure restrictions keeping jib gauge at the quick down function from disconnect coupling on moving OR repair or the boom function replace jib cylinder OR manifold replace jib cylinder 2 34 22 before serial counterbalance valves number 153 and OR consult Genie 234 22 before serial Industries Service number 304 Move the Department jib toggle switch in the DOWN direction 2 34 22 after serial number 152 and Z34 22N after serial number 303 Hold the function enable toggle Switch to either side and move the jib toggle Switch in the DOWN direction less than 3200 PSI Repair or replace jib cylinder OR replace jib cylinder counterbalance valves OR platform rotate jib function manifold could have an internal defect Consult Genie Industries Service Department Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 5 93 Section 5 Troubleshooting Flow Charts First Edition Third Printing Chart 24 Steer Left Function inoperative Z 34 22 b
360. rst Edition Third Printing TABLE B PROCEDURES B 10 Test the Horn A properly functioning horn is essential to safe machine operation The horn is activated at the platform controls and sounds at the ground as a warning to ground personnel An improperly functioning horn will prevent the operator from alerting ground personnel of hazards or unsafe conditions 1 Turn the key switch to platform control and pull out the Emergency Stop button to the ON position at both the ground and platform controls 2 Push down the horn button at the platform controls Result The horn should sound If necessary the horn can be adjusted to obtain the loudest volume by turning the adjustment Screw near the wire terminals on the horn B 11 Test the Foot Switch A properly functioning foot switch is essential to safe machine operation Machine functions should activate and operate smoothly as long as the foot Switch is pressed down and promptly stop when the foot switch is released An improperly functioning foot switch can cause an unsafe working condition 1 Turn the key switch to platform control and pull out the Emergency Stop button to the oN position at both the ground and platform controls 2 Without pressing down the foot switch attempt to operate the machine functions Result The machine functions should not operate 3 Press down the foot switch and operate the machine functions Result The machine funct
361. s AH and AC or BH and BC 2 34 22 after serial number 1733 and 2 34 22 after serial number 2226 items CK and CU Activate the primary boom RETRACT function Replace defective directional valve function inoperative Continued on the next page 5 58 Genie 7 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 5 Troubleshooting Flow Charts CHART 14 Install a 0 to 5000 PSI Adjust the system relief moles Tn the 0 to 345 bar pressure valve see Repair page gauge at the quick Section disconnect coupling on 2 34 22 before serial the function manifold number 1734 and 2 34 22 before serial Z 34 22N before serial number 153 and number 2227 Z34 22N before serial item AB or BB number 304 Move the 2 34 22 after serial primary boom extend number 1733 and retract function toggle Z 34 22N after serial Switch in the RETRACT number 2226 item direction and check the CR OR repair or pressure replace cylinder s or 2 34 22 after serial cylinder s number 152 and counterbalance valve s Z34 22N after serial OR function manifold number 303 Hold the could have an internal function enable toggle defect Consult Genie switch to either side and Industries Service move the primary boom Department extend retract function toggle switch in the RETRACT direction and check the pressure 3200 PSI Check for mechanical restrictions keeping the primary boom extend function from
362. ss connector 20V or more See Chart 29A Motor Controller Fault Code 21 Throttle Fault Replace the drive controller Repair open in the wht 1 wire circuit from terminal 4 on the drive controller to TB30 to pin 10 on the motor controller harness connector Replace the drive controller Repair open in the wht blk 1 wire from terminal on the drive controller to TB31 to pin 11 on the motor controller harness connector 5 110 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 5 Troubleshooting Flow Charts CHART 29 Press down the foot 20V or Repair open in org red Continued from the previous page sive controler in etter terminal 5 on he ive direction Check voltage controller at TB16 Press down the foot 2 Repair open red 5 w and move the wire a from terminal rive controller in either 13 on LS3 to TB16 direction Check voltage at terminal 13 on LS3 Press down the foot a switch and move the Replace LS3 drive controller in either direction Check voltage at terminal 14 on LS3 Press down the foot zu Repair open in blk 5 Switch and move the wire circuit from TB12 to drive controller in either terminal 14 153 direction Check voltage at TB12 Press down the foot 20V or Repair open in blu wht 3 switch and move the more wire circuit from the drive controller in eith
363. ss down the foot Replace the diode on switch and move any the blk red wire on boom boom function toggle function speed controller switch and check OR repair open in wht voltage at TB6 red 3 wire circuit from boom function speed controller to TB6 Continued from the previous page 20V or more Press down the foot Repair open in wht red switch and move any wire from TB6 to the boom function toggle proportional valve switch and check voltage at the wht red wire on the proportional valve item AU or BU or CH 20V or more Repair open in brn ground wire circuit to the proportional valve OR troubleshoot lift and drive functions individually OR consult Genie Industries Service Department Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 5 33 Section 5 Troubleshooting Flow Charts First Edition Third Printing Chart 9 Primary Boom Up Function inoperative Be sure key switch is in the appropriate position Be sure the Emergency Stop buttons are pulled out to the on position Be sure the battery packs are properly connected and fully charged Turn key switch to ground controls and pull both Emergency Stop buttons out to the ON position 2 34 22 before serial number 153 and Z34 22N before serial number 304 Move the primary boom toggle switch TS12 in the uP direction and check voltage on the wht red 6 wire at the boom function proportional valve coil item AU or BU
364. stall the relief valve cap AWARNING 11 07 hazard Do not adjust the relief valve higher than specified 6 Repeat steps 2 and 3 to confirm the relief valve pressure setting Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 7 49 Section 7 Repair Procedures First Edition Third Printing MANIFOLDS How to Adjust the Turntable Rotate Relief Valves Perform this procedure with the boom in the stowed position 1 Connect a 0 to 3000 psi 0 to 206 bar pressure gauge to the test port on the function manifold 2 Turn the key switch to ground control and pull out the Emergency Stop button to the position 3 Z 34 22 before serial number 153 and Z 34 22N before serial number 304 Move the turntable rotate right left toggle Switch in the direction until turntable stops against the rotation stop Observe the pressure reading on the pressure gauge Z 34 22 after serial number 152 and Z 34 22N after serial number 303 Hold the function enable toggle switch to either side and move the turntable rotate right left toggle switch in the RIGHT direction until turntable stops against the rotation stop Observe the pressure reading on the pressure gauge Turntable rotate relief valve specifications Z 34 22 before serial number 674 1750 psi 121 bar from serial number 674 to 1733 Not adjustable after serial number 1733 1100 psi 76 bar Z 34 22N before serial number 935 1750 psi 121 bar from serial n
365. start and finish lines TABLE B PROCEDURES 6 Bring the machine to maximum drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line 7 Continue at full speed and note the time when the machine reference point passes over the finish line Drive speeds maximum Z 34 22 before serial number 1734 Drive speed stowed 35 1 torque hubs 4 mph 6 4 km h 40 ft 6 8 sec 12 2 m 6 8 sec Drive speed stowed 49 1 torque hubs 3 1 mph 5 km h 40 ft 9 1 sec 12 2 m 9 1 sec after serial number 1733 Drive speed stowed 47 1 torque hubs 3 7 mph 6 km h 40 ft 7 5 sec 12 2 m 7 5 sec Drive speeds maximum Z 34 22N before serial number 2227 Drive speed stowed 3 4 mph 5 5 km h 35 1 torque hubs 40 8 12 2 m 8 sec Drive speed stowed 2 8 mph 4 5 km h 49 1 torque hubs 40 10 12 2 m 10 after serial number 2226 Drive speed stowed 3 1 mph 5 km h 47 1 torque hubs 40 9 12 2 m 9 sec 36540 Genie 7 34 22 amp Genie Z 34 22N Section 4 Scheduled Maintenance Procedures First Edition Third Printing TABLE B PROCEDURES B 15 Test the Drive Speed Raised or Extended Position Proper drive function movement is 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
366. stowed position 4 Swing out the battery packs to expose the turntable bearing bolt access hole TABLE C PROCEDURES 5 Check to ensure that each bearing mounting bolt under the drive chassis is torqued in specified order to 190 ft lbs 258 Nm 9 1 44 oO 0 7 us OF D N MEE 30 04 149 N A O15 40 O 12 2 10 2 Bolt torque sequence Z 34 22 before serial number 1735 and Z 34 22N before serial number 2240 1 4 ul 7 aec y b X 6O 3 V XP 2 A A 5 O 8 Bolt torque sequence Z 34 22 after serial number 1734 and Z 34 22N after serial number 2239 Part No 36540 Genie Z 34 22 amp Genie Z 34 22N Section 4 Scheduled Maintenance Procedures First Edition Third Printing TABLE C PROCEDURES C 3 Check the Free wheel Configuration Proper use of the free wheel configuration is essential to safe machine operation The free wheel configuration is used primarily for towing A machine configured to free wheel without operator knowledge may cause death or serious injury and property damage AWARNING Collision hazard Select a work site that is firm and level Component damage hazard If the machine must be towed do not exceed 2 mph 3 2 km h 1 Chockthe steer wheels to prevent the machine from rolling 2 Center a lifting jack of ample capacity 15000 1 5 6804 kg under the drive chassis between the non steering wheels 3 Liftt
367. t 3 Locate the removal tab on the bottom or top side of the component 4 Use the Wago tool to gently pry up on the tab of the component and remove it 7 36 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 7 Repair Procedures 7 1 Auxiliary Pump How to Test the Auxiliary Pump 1 Disconnect and plug the high pressure hydraulic hose from the auxiliary pump 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 When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 2 Connect a 0 to 5000 psi 0 to 350 bar pressure gauge to the high pressure port on the pump 3 Turn the key switch to ground control and pull out the Emergency Stop button to the position at both ground and platform controls Hydraulic Pumps 4 Activate any function using auxiliary power Result If the pressure gauge reads 3200 psi 220 bar immediately stop The pump is good Result If pressure fails to reach 3200 psi 220 bar the pump is bad and will need to be serviced or replaced 5 Remove the pressure gauge and reconnect the hydraulic hose How to R
368. t Y N R Refer to Table C C 1 Boom wear pads C 2 Turntable bearing bolts C 3 Free wheel configuration C 4 Grease rotation bearing C 5 Drive hub oil C 6 Platform rotator Checklist D Y N R Refer to Table D D 1 Hydraulic oil D 2 Wheel bearings Part No 36540 Genie Z 34 22 amp Genie Z 34 22N Section Scheduled Maintenance Inspections First Edition Third Printing This page intentionally left blank 3 6 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 4 Scheduled Maintenance Procedures 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 hourly quarterly annually and every 2 years as specified on the Maintenance Inspection Report Failure to properly complete each AWARNING inspection when required may cause death serious injury or substantial machine damage Immediately tag and remove from service damaged or malfunctioning machine Repair any machine damage or malfunction before operating machine Unless otherwise specified perform each procedure with the machine in the following configuration Machine parked on a flat level surface Boomin the stowed position Turntable rotated with the boom betwee
369. t is not properly supported Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 7 18 Section 7 Repair Procedures First Edition Third Printing PLATFORM COMPONENTS How to Bleed the Platform Rotator This procedure will require two people 1 Turn the key switch to ground controls and pull out the Emergency Stop button to the position 2 Z 34 22 before serial number 153 and Z 34 22N before serial number 304 Move the primary boom toggle switch in the up direction until the platform is approximately 6 feet 1 8 m off the ground Z 34 22 after serial number 152 and Z 34 22N after serial number 303 Hold the function enable toggle switch to either side and move the primary boom toggle switch in the uP direction until the platform is approximately 6 feet 1 8 m off the ground 3 Connect clear hose to the top bleed valve Place the other end of the hose in a container to collect any discharge Open the top bleed valve but do not remove it Z 34 22 before serial number 153 and Z 34 22N before serial number 304 Move the platform rotate toggle switch to the right for approximately 5 seconds then release it Repeat three times Z 34 22 after serial number 152 and Z 34 22N after serial number 303 Hold the function enable toggle switch to either side and move the platform rotate toggle switch to the right for approximately 5 seconds then release it Repeat three times AWARNING Crushing hazard Keep clea
370. t lbs 68 Nm 7 42 Genie 7 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 7 Repair Procedures BC MANIFOLDS ele Nir C 3 Q 75 BD WS uA 0 3 ZS OO On S s 99 8 ed 9 d 8 ag Ol O Gp G 18 B ge C2 8 m S S O e E Y M D a ie lt BO 8257 BN QE 2 9 36540 Genie Z 34 22 amp Genie Z 34 22N 7 43 Section 7 Repair Procedures First Edition Third Printing IRR M MANIFOLDS 8 3 Function Manifold Components Z 34 22 after serial number 1733 and Z 34 22N after serial number 2226 The function manifold is mounted to the turntable under the ground controls index 4 Schemdic No Description Item Function Torque 1 position 4 way spool valve Platform level up down 10 12 ft Ibs 14 16 Nm 2 Counterbalance valve CB uu Platform level down 35 40 ft Ibs 47 54 Nm 3 Counterbalance valve GG auus Platform level 35 40 ft lbs 47 54 Nm 4 Relief valve 1100 psi 75 8 bar CD Turntable rotate left rig
371. t meter to terminals B and M on the motor controller Press down the foot switch and slowly move the drive controller from neutral to full stroke in the FORWARD direction Voltage should ramp up from OV to 48V Connect wht wire on forward reverse contactor PR2 Connect a volt meter to terminals B and M on the motor controller Press down the foot switch and slowly move the drive controller from neutral to full stroke in the FORWARD direction Voltage should ramp up from OV to 48V Repair open in cable circuit from the motor controller to PR2 to the drive motors OR repair open in the ground wire circuit from PR2 coils to ground OR ee or replace PR2 OR repair or replace the bad motor OR consult Genie Industries Service Department CHART 28 Replace the motor controller Disconnect the battery packs from the machine and disconnect the positive cable from terminal A2 on the motor controller Using an ohmmeter check resistance in both directions across terminals A2 and B on the motor controller Resistance should be high in one direction and low in the other Replace motor controller Repair or replace the bad motor OR consult Genie Industries Service Department Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 5 105 Section 5 Troubleshooting Flow Charts Chart 28A Brake Function inoperative Z 34 22 before serial number 1734 and Z 34 22N before serial number 2227
372. t pump motor Z 34 22 from serial number 153 to 1733 and Z 34 22N from serial number 304 to 2226 Hold the function enable switch TS19 to either side and move the primary boom extend retract toggle switch TS13 in the RETRACT direction and check voltage at the positive terminal on the lift pump motor Z 34 22 after serial number 1733 and Z 34 22N after serial number 2226 Hold the function enable switch TS55 to either side and move the primary boom extend retract toggle switch TS63 in the RETRACT direction and check voltage at the positive terminal on the lift pump motor Continued on the next page Check for continuity in the ground cable circuit from lift pump motor to ground Replace the ground cable on the lift pump motor OR repair open in the ground cable from the battery packs no continuity Repair or replace the lift pump motor Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 5 Troubleshooting Flow Charts SS SS CHART 2 2 34 22 before serial Z 34 22 before serial ELE an the number 153 and number 153 and 2 34 page Z 34 22N before serial 22N before serial number 304 Move the number 304 Repair or primary boom extend replace the positive retract toggle switch in cable from the lift pump the RETRACT direction motor to PR3 and check voltage at the Z 34 22 after serial positive cable on the number 152 and output si
373. t switches LS2 and LS3 are not being activated when the primary and secondary booms are in the stowed position Be sure the battery packs are properly connected and fully charged Turn key switch to ground controls and pull yes both Emergency Stop buttons out to the position Check the status indicator light on the motor controller to see if there is a fault Is there a fault no Check voltage at TB22 ov 24V Check voltage at the wht 7 wire on the input side of LS1 24V Check voltage at TB49 ov 24V Check voltage at the blk 6 wire on the input side of LS2 24V Check voltage at TB50 24V Continued on the next page Chart 34 Refer to the fault code chart at the beginning of this section to determine the cause of the fault Repair open in blk 22 wire from key switch to Repair open in wht 7 wire from TB22 to the input side of LS1 Check to make sure LS1 is being activated when the primary boom is retracted OR repair open in blk 7 wire from the output side of LS1 to TB49 OR replace LS1 OR replace 1 Repair open blk 6 wire from TB49 to the input side of LS2 Check to make sure LS2 is not being activated when the primary boom is in the stowed position OR repair open in wht 6 wire from the output side of LS2 to TB50 OR replace LS2 contacts OR replace LS2 Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 5
374. tch at ground control and toggle switch at platform control has been restored and jib down function is still inoperative continue trouble shooting from beginning of chart Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 5 91 Section 5 Troubleshooting Flow Charts CHART 23 Continued from the previous page Turn key switch to ground controls and pull both Emergency Stop buttons out to the position 2 34 22 before serial number 153 and Z34 22N before serial number 304 Move platform jib toggle switch In the DOWN direction and check voltage on the wht wire on the jib down directional valve coil item Z 34 22 after serial number 152 and Z34 22N after serial number 303 Hold the function enable toggle Switch to either side and move jib toggle switch in the DOWN direction and check voltage on the wht wire on the jib down directional valve coil item E 20V or more Continued on the next page Z 34 22 before serial number 153 and Z34 22N before serial number 304 Move the jib toggle switch in the DOWN direction and check voltage at TB44 Z 34 22 after serial number 152 and Z34 22N after serial number 303 Hold the function enable toggle switch to either side and move the jib toggle switch in the DOWN direction and check voltage at TB44 Turn key switch to platform
375. tem CH 24N Continued on page 62 2 34 22 before serial number 153 and Z34 22N before serial number 304 Move the 24V turntable rotate toggle switch in the LEFT direction and check the voltage at TB6 2 34 22 after serial number 152 and 234 22 after serial number 303 Hold the function enable toggle switch to either side and move the turntable rotate toggle switch in the LEFT direction and check the voltage at TB6 Turn key switch to 24V platform controls and pull both Emergency Stop buttons out to the ON position With the boom function speed controller turned to 9 press down the foot switch and move the turntable rotate toggle switch Z 34 22 before serial number 1734 and Z 34 22N before serial number 2227 TS1 Z 34 22 after serial number 1733 and Z 34 22N after serial number 2226 TS12 in the LEFT direction Check voltage at TP6 ov Continued on the next page Repair open in wht red 6 wire circuit from TB6 to the boom function proportional valve coil OR repair open in the ground wire circuit to the boom function proportional valve coil Repair open in blk red wire circuit from TP6 to to TB6 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 5 Troubleshooting Flow Charts CHART 15 Press down the foot Repair open in wht red switch and move the wire circuit through turntable rotate toggle boom function
376. the ON position With the boom function speed controller turned to 9 press down the foot switch and move the turntable rotate toggle switch Z 34 22 before serial number 1734 and Z 34 22N before serial number 2227 TS1 Z 34 22 after serial number 1733 and Z 34 22N after serial number 2226 7512 in the RIGHT direction Check voltage at TB5 24V Troubleshoot the turntable rotate toggle switch OR replace diode on toggle switch OR repair open in wht 5 wire circuit from toggle switch to TB5 OR replace toggle switch 24V Repair open in wht blk 5 wire circuit from TB5 to turntable rotate right directional valve coil OR repair open in brn ground wire circuit to the manifold ov Repair open in wht blk 3 wire circuit to TB5 Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 5 67 Section 5 Troubleshooting Flow Charts First Edition Third Printing CHART 16 Disconnect the wire to the turntable rotate right directional valve coil Test the resistance of the valve coil See Repair Section Continued from the previous page Exchange the turntable rotate and secondary boom directional valves items AE and AK or items BE and BK or items CX and CJ Activate the turntable rotate RIGHT function Install a 0 to 5000 PSI 0 to 345 bar pressure gauge at the quick disconnect coupling on the function manifold 2 34 22 before serial number 153 and Z34 22N before serial num
377. the pin retaining fasteners from the upper compression arm pivot pins Do not remove the pins Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 7 Repair Procedures 28 Position the lifting strap from an overhead crane at the center of the control box side upper compression arm then remove it from the machine Repeat this step for the engine side upper compression arm Crushing hazard If the overhead AWARNING crane is not properly attached the upper compression arm may become unbalanced and fall when itis removed from the machine 29 Remove the pin retaining fastener from the rod end of the secondary boom lift cylinder Use a soft metal drift to remove the pin Secure the cylinder from moving 30 Remove the pin retaining fastener from the lower pivot pin on the compression link Use a soft metal drift to remove the pin 31 Attach the strap from an overhead crane to the upper secondary boom 32 Remove the pin retaining fastener from the upper secondary boom to lower mid pivot pivot pin Use a soft metal drift to remove the pin 33 Remove the upper secondary boom with compression link from the machine AWARNING Crushing hazard If the overhead crane is not properly attached the upper secondary boom with compression link may become unbalanced and fall when it is removed from the machine SECONDARY BOOM COMPONENTS 34 Remove the cable covers from the top of the low
378. ting Section 2 Specifications SPECIFICATIONS SAE FASTENER TORQUE CHART This chart is to be used as a guide only unless noted elsewhere in this manual A574 High Strength Grade 8 Black Oxide Bolts LUBED DRY LUBED DRY LUBED Wm mies Nm Nm _ Nm _ 9 113 T 110 140 130 120 T60 140 LUBED DRY LUBED ribs 13 T8 1 20 23 33 26 37 14 7 15 8 LUBED I 20 i 0 Ej lt 24 27 1 44 7 50 1 67 8 81 3 108 4 122 162 176 217 244 25 27 44 49 70 33 9 28 4 36 6 32 5 59 6 51 5 66 4 58 3 88 Nm 94 7 82 7 108 4 92 1 149 126 162 142 203 176 250 189 251 244 325 271 515 433 569 474 827 591 37 50 di 57 773 20 64 867 one 12 80 108 4 110 149 120 o 122 120 3162 130 vs LH H0 149 3150 205 160 18 130 176 370 230 180 280 379 16 20 298 30 406 310 420 va 12 320 483 430 583 450 610 610 314 30 474 470 637 500 68 670 908 759 480 650 640 867 580 922 910 1233 1044 12 530 718 710 o2 750 1016 990 1342 1139 m 1749 1477 s 312 s70 908 e90 1206 1080 1464 1440 1952 1220 1654 E 2074 312 930 1260 1240 1681 1510 2047 2010 2725 1700 2504 3620 2 312 eo 2067 METRIC FASTENER TORQUE CHART This chart
379. ting strap from an overhead crane to the jib boom Remove the pin retaining fastener from the jib boom pivot pin at the jib boom bellcrank Use a soft metal drift to remove the pin then remove the jib boom from the jib boom bellcrank AWARNING Crushing hazard The jib boom will fall when the pin is removed if it is not properly supported Remove the pin retaining fasteners from the jib boom lift cylinder rod end pivot pin Do not remove the pin Remove both of the jib boom compression arms from the bellcrank 10 Attach a lifting strap from an overhead crane to the rod end of the jib boom lift cylinder 11 Use a soft metal drift to remove the jib boom lift cylinder rod end pivot pin then remove the jib boom lift cylinder from the jib boom bellcrank AWARNING Crushing hazard The jib boom lift cylinder will fall when the pin is removed if it is not properly supported Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 7 Repair Procedures 12 Support and secure the jib boom bellcrank to an appropriate lifting device 13 Remove the pin retaining fasteners from the slave cylinder rod end pivot pin Do not remove the pin 14 Remove the pin retaining fasteners from the jib boom mounting weldment at the jib boom bellcrank Use a soft metal drift to remove the pin 15 Use a soft metal drift to remove the slave cylinder rod end pivot pin 16 Remove the jib boo
380. tion Z 34 22 before serial number 153 and Z34 22N before serial number 304 Move platform rotate toggle switch in the RIGHT direction and check voltage on the yel wire on the platform rotate right directional valve coil item B Z 34 22 from serial number 153 to 1733 and Z 34 22N from serial number 304 to 2226 Hold the function enable toggle switch to either side and move platform rotate toggle switch in the RIGHT direction and check voltage on the yel wire on the platform rotate right directional valve coil item B Z 34 22 after serial number 1733 and Z 34 22N after serial number 2226 Hold the function enable toggle switch to either side and move platform rotate toggle switch in the RIGHT direction and check voltage on the blu wire on the platform rotate right directional valve coil item B 24V Continued on the next page First Edition Third Printing Z 34 22 before serial number 153 and Z34 22N before serial 24V number 304 Move the platform rotate toggle switch in the RIGHT direction and check voltage at TB18 Z 34 22 after serial number 152 and Z34 22N after serial number 303 Hold the function enable toggle switch to either side and move the platform rotate toggle switch in the RIGHT direction and check voltage at TB18 Turn key switch to platform controls and 24V pull both Emergency Stop buttons out to the ON position With the boom function speed controller turned to 9
381. tion enable toggle switch to either side and move the secondary boom toggle switch in the up direction and check voltage on the blu 10 wire on the secondary boom up directional valve coil item E 2 34 22 after serial number 1733 and Z 34 22N after serial number 2226 Hold the function enable toggle switch to either side and move the secondary boom toggle switch in the up direction and check voltage on the blu 10 wire on the secondary boom up directional valve coil item AB Continued from page 42 24V Continued on the next page 2 34 22 before serial number 153 and Z34 22N before serial 24V number 304 Move the secondary boom toggle switch in the uP direction and check voltage at TB10 Z 34 22 after serial number 152 and Z34 22N after serial number 303 hold the function enable toggle switch to either side and move the secondary boom toggle switch in the up direction and check voltage at TB10 Turn key switch to oV Repair open in blu 3 platform controls and wire circuit to TB10 pull both Emergency Stop buttons out to the ON position With the boom function speed controller turned to 9 press down the foot switch and move the secondary boom toggle switch in the uP direction and check voltage at TB10 Repair open in blu 10 wire circuit from TB10 to secondary boom up directional valve coil OR repair open in the ground wire circuit to manifold 24V Troubleshoot the se
382. tion should be operating Begin troubleshooting from the beginning of this chart 20V or more 20V or more 20V or more 20V or more Repair open in red wire circuit from input side of the key switch to the input side of the remote brake release jack Replace remote brake release button OR replace the remote brake release jack 2 34 22 before serial number 1734 and Z 34 22N before serial number 2227 Repair open in red wht wire circuit from the output side of the remote brake release jackto TB46 2 34 22 after serial number 1733 and Z 34 22N after serial number 2226 Repair open in red wht wire circuit from the output side of the remote brake release jack to 48 27 34 22 before serial number 1734 and Z 34 22N before serial number 2227 Repair open in red wht wire circuit with diode from 46 to TB47 OR replace the diode 5 130 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 6 Schematics Observe and Obey 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 damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Before Troubleshooting Read understand and obey the safety rules and operating instructions printed in the Genie Z 34 22 amp Genie Z 34 22N Op
383. to rotate the platform 160 degrees How to Remove the Platform Rotator When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Remove the platform See 2 1 How to Remove the Platform 2 Tag disconnect and plug the hydraulic hoses from the platform rotate manifold Cap the manifold fittings 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 Support the platform mounting weldment but do not apply any lifting pressure PLATFORM COMPONENTS 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 Support the platform rotator with a suitable lifting device Do not apply any lifting pressure Remove the pin retaining fasteners from the jib boom and leveling links to platform rotator pivot pins Do not remove the pins Support the jib boom jib boom cylinder and leveling links with an overhead crane Use a soft metal drift to drive both pivot pins out Remove the platform rotator from the machine ACAUTION Crushing hazard The platform rotator may become unbalanced and fall if i
384. toggle switch in the LEFT switches to the red wire direction Check the on the boom function voltage at the red wire speed controller on the boom function speed controller Continued from the previous page Press down the foot Repair open in ground switch and move the wire circuit from the turntable rotate function boom function speed toggle switch in the LEFT controller to ground OR direction Check the replace the boom voltage at the blk red function speed wire on the boom controller function speed controller Repair open in blk red wire from the boom function speed controller to TB6 Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 5 61 Section 5 Troubleshooting Flow Charts First Edition Third Printing CHART 15 Turn key switch to ground controls and pull both Emergency Stop buttons out to the ON position 2 34 22 before serial number 153 and Z34 22N before serial number 304 Move the turntable rotate toggle switch in the LEFT direction and check voltage on the wht 4 wire on the turntable rotate directional valve coil item AF 2 34 22 from serial number 153 to 1733 and Z 34 22N from serial number 304 to 2226 Hold the function enable toggle switch to either side and move the turntable rotate toggle switch in the LEFT direction and check voltage on the wht 4 wire on the turntable rotate directional valve coil item AF or BF 2 34 22 after serial number 1733 and Z 34 22N
385. tor and the pump by removing the from the motor ut leave all the hoses connected Visually check the coupling connection Genie Industries Service Department bad Replace the auxiliary power unit no Check continuity in the continuity ground wire circuit from Replace the ground cable from the auxiliary the negative terminal on auxiliary power unit to ground pump to ground continuity Replace the auxiliary pump motor Part No 36540 Genie 7 34 22 amp Genie Z 34 22N 5 17 Section 5 Troubleshooting Flow Charts First Edition Third Printing CHART 3 Hold the auxiliary pump toggle switch and move any boom function Continued from the previous page toggle switch Check voltage at the grn wht wire on PR3 ov Check voltage at the center terminal on the auxiliary pump toggle switch 24V Hold the auxiliary pump toggle switch and check voltage at TB27 24V 24N Hold the auxiliary pump toggle switch and check the voltage red 27 wire on control relay Z 34 22 before serial number 1734 and Z 34 22N before serial number 2227 CR2 Z 34 22 after serial number 1733 and Z 34 22N after serial number 2226 CR3 24N Continued on the next page no continuity Check continuity of the brn ground wire circuit Repair open in the brn ground wire circuit from from to ground to ground continuity
386. tput side of platform switch internal cam is contact for platform controls contact of the activating the platform controls key switch controls contact Replace the key switch 20V or more Check voltage at TB22 Repair open in blk 22 wire circuit from key switch to TB22 20V or more Check voltage at the input side of the platform OV wire circuit from TB22 to Emergency Stop button platform Emergency contact Stop button OR repair open in ground wire circuit from platform controls to ground Repair open in blk 2 20V or more Check voltage at the output side of platform Emergency Stop button contact Check to see if the Replace the platform Emergency Stop button Emergency Stop button is activating the contact contact 20V or more Replace the platform Emergency Stop button Continued on the next page Part No 36540 Genie 2 34 22 amp Genie Z 34 22N 5 27 Section 5 Troubleshooting Flow Charts CHART 7 Continued from the previous page Check the voltage at the input side of the foot switch 20V or more Press down foot switch and check voltage on Before serial number 747 the wht wire at the foot switch After serial number 746 the blu wht wire at the foot switch 20V or more Press down foot switch and check voltage at 12 20V or more Press
387. ts A 4 Check the Hydraulic Oil Level 5 Check for Hydraulic Leaks E A 6 Test the Platform and Ground Controls A 7 Test the Auxiliary Power Operation A 8 Test the Tilt Sensor A 9 Test the Limit Switches E A 10 Test the Lift Drive Select Switch if equipped A 11 Perform 30 Day 50 Hour Service Table B B 1 Check the Batteries 2 Inspect the Electrical Wiring B 3 Inspect the Tires and Wheels including lug nut torque B 4 Confirm the Proper Brake Configuration B 5 Check the Oil Level in the Drive Hubs Ea 3 2 Genie 7 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section Scheduled Maintenance Inspections MAINTENANCE TABLES Wi Cold Deal Table B continued Tools are New parts 2 viri required required required required suggested B 6 Test the Key Switch B 7 Test the Emergency Stop Buttons B 8 Test the Ground Control Override B 9 Test the Platform Self leveling B 10 Test the Horn B 11 Test the Foot Switch B 12 Test the Drive Enable System B 13 Test the Drive Brakes B 14 Testthe Drive Speed Stowed Position B 15 Testthe Drive Speed Raised or Extended Position BN B 16 Testthe Alarm Package if equipped B 17 Test Turntable Rotation Stop B 18 Check the Electrical Contactors B 19 Perform Hydraulic Oil Analysis See D 1
388. u Platform rotate left Solenoid valve 2 position 3 way Jib boom Orifice plug 0 030 inch 0 89 mm F Jib boom platform rotate circuit Added after serial number Z 34 22 781 and Z 34 22N 1030 MANIFOLDS Solenoid valve 2 position 3 way Jib boom UP 8 10 ft lbs 11 14 Nm 8 10 ft lbs 11 14 Nm 8 10 ft lbs 11 14 Nm 8 10 ft lbs 11 14 Nm F Wee oe 0 P eU 2 Plug Torque Specifications 2 2 Valve Coil Resistance Specification Description Hex Size Torque Description Measurement SAE No 2 1 8 50 in Ibs 6 Nm 2 position 3 way valve 20V 23 5 to 24 50 SAE No 4 3 16 13 ft lbs 18 Nm schematic items A B D and E Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 7 51 Section 7 Repair Procedures First Edition Third Printing rm s X a MANIFOLDS 8 6 Jib Boom Platform Rotate Manifold Components Z 34 22 from serial number 1734 to 2005 and Z 34 22N from serial number 2227 to 2771 The jib boom platform rotate manifold is mounted to the jib boom 1 Solenoid valve 2 position 3 way Funes Jib UD eiiis 8 10 ft lbs 11 14 Nm 2 Solenoid valve 2 position 3 way Platform rotate right 8 10 ft lbs 11 14 Nm Orifice plug 0 025 inch 0 64
389. um capacity 500 Ibs 227 kg Wheel width 7in 18 cm Operational dimensions ee Wheel lugs Height platform maximum 34 ft 4 in 34 ft 8 in Front 8 Q 5 18 10 5 10 6 m Rear 9 Q 5 a 18 Height working maximum 40 ft 4 in 40 ft 8 in Lug nut torque 125 ft lbs 169 5 Nm 12 3 12 4 m Fluid Capacities Horizontal reach maximum 22 ft 4 in 22 ft 4 in 6 8m 6 8m Z 34 22 before serial number 809 and Z 34 22N before serial number 1116 Turntable tailswing 0 0 Hydraulic tank capacity 5 gallons 3 18 9 liters Wheelbase 6 ft 2 in 6 ft 2 in 1 9m 19m Hydraulic system 7 gallons 7 including tank 26 5 liters Turning radius 12 ft 9 in 13 ft 1 in outside 3 9 m 4m 2 34 22 after serial number 808 and 7 7 Z 34 22N after serial number 1115 Turning radius 6 ft 5 ft 8 in Hydraulic tank capacity 4 gallons inside 1 8 m 1 7 m 15 1 liters Turntable rotation degrees 355 355 Hydraulic system 6 gallons Platform rotation degrees 160 160 including tank 22 7 liters Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 2 1 Section 2 Specifications SPECIFICATIONS Performance Specifications Drive speeds maximum Z 34 22 before serial number 1734 Drive speed stowed 35 1 torque hubs 4 mph 40 ft 6 8 sec Drive speed stowed 49 1 torque hubs
390. umber 304 Move the primary boom toggle switch in the UP direction and check voltage on the red 1 wire on the primary boom up oV directional valve coil item AD or BD or CU Z 34 22 after serial number 153 and Z 34 22N after serial number 304 Hold the function enable toggle switch to either side and move the primary boom toggle switch in the uP direction and check voltage on the red 1 wire on the primary boom up directional valve coil item AD or BD or CU 24V Continued on the next page First Edition Third Printing Z 34 22 before serial number 153 and Z34 22N before serial 24V number 304 Move the primary boom toggle switch in the uP direction and check voltage at 1 2 34 22 after serial number 152 and Z34 22N after serial number 303 Hold the function enable toggle switch to either side and move the primary boom toggle switch in the UP direction and check voltage at TB1 Turn key switch to platform controls and oV pull both Emergency Stop buttons out to the ON position With the boom function speed controller turned to 9 press down the foot switch and move the primary boom toggle switch Z 34 22 before serial number 1734 and Z 34 22N before serial number 2227 TS3 Z 34 22 after serial number 1733 and Z 34 22N after serial number 2226 TS11 in the uP direction Check voltage at TB1 24V Troubleshoot the primary boom toggle switch at ground controls OR replace the diode
391. umber 935 to 2226 Not adjustable after serial number 2226 1100 psi 76 bar Turn the machine off Hold the relief valve and remove the cap Z 34 22 Before serial number 674 items AP and AQ After serial number 1733 item CD Z 34 22N Before serial number 935 items AP and AQ After serial number 2226 item CD Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the relief valve cap AWARNING Tip over hazard Do not adjust the relief valves higher than specified Repeat steps 2 and 3 to confirm the relief valve pressure setting Z 34 22 before serial number 674 and Z 34 22N before serial number 935 Repeat steps 2 through 6 to adjust the turntable rotate left relief valve If adjusting the turntable rotate left hold the switch to the left and adjust the left relief valve item AQ function manifold 7 50 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 7 Repair Procedures 8 5 Jib Boom Platform Rotate Manifold Components 7 34 22 before serial number 1734 and Z 34 22N before serial number 2227 The jib boom platform rotate manifold is mounted to the jib boom oa A ON Solenoid valve 2 position 3 way Bue Platform rotate right Orifice plug 0 025 inch 0 76 mm C Platform rotate circuit Solenoid valve 2 position 3 way Da
392. ur reference point on the machine crosses the start line 24 Continue at full speed and note the time when the reference point crosses the finish line 7 4 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 7 Repair Procedures 25 Adjust max out trimpot on the drive circuit board to achieve the specified drive speed time refer to table below Turn the high range trimpot clockwise to decrease the time or counterclockwise to increase the time Drive controller specifications Brake board Threshold 0 16 amps when pump motor turns oN Max out 0 91 amps when pump motor turns orr Drive board Threshold 0 8 to 0 9V DC when amp output is 0 28 to 0 3 amps Max out 5 to 5 2V DC with boom stowed and joystick in full forward position Lo range 2 4 to 2 7V DC with boom raised and joystick in full forward position Drive speeds maximum Z 34 22 stowed position 49 1 drive hubs 3 1 mph 5 km h 40 ft 9 1 sec 12 2 m 9 1 sec 35 1 drive hubs 4 mph 6 4 km h 40ft 6 8 sec 12 2 m 6 8 sec Drive speeds maximum Z 34 22N stowed position 49 1 drive hubs 2 8 mph 4 5 km h 40 10 12 2 10 sec 35 1 drive hubs 3 4 mph 5 5 km h 40fU8 sec 12 2 m 8 sec Drive speed 0 6 mph 1 km h booms raised or extended 40 ft 40 12 2 m 40 sec PLATFORM CONTROLS Drive Controller Adjustments Z 34 22 from serial number 153 to 1733 Z 34 22N from
393. ve continue trouble shooting from beginning of chart Part No 36540 Genie Z 34 22 amp Genie Z 34 22N Section 5 Troubleshooting Flow Charts First Edition Third Printing CHART 22 0 or infinite ohms Disconnect the wires from the jib up directional valve coil Test the resistance of the valve coil See Repair Section Continued from the previous page Replace jib up directional valve coil Exchange the jib up function jib down directional operates valves item A and Activate the jib up function Replace defective directional valve function inoperative Install a 0 to 3000 PSI 0 Check for mechanical to 207 bar pressure restrictions keeping jib gauge at the quick up function from moving disconnect coupling on OR repair or replace jib the boom function cylinder OR replace jib manifold cylinder counterbalance 2 34 22 before serial valves OR consult number 153 and Genie Industries Service Z34 22N before serial Department number 304 Move the jib toggle switch in the UP direction Z 34 22 after serial number 152 and Z34 22N after serial number 303 Hold the function enable toggle switch to either side and move the jib toggle switch in the UP direction less than 2800 PSI Repair or replace jib cylinder OR replace jib cylinder counterbalance valves OR platform rotate jib function manifold could have an internal defect Consult
394. ve coil item AU or BU Z 34 22 after serial number 1733 and Z 34 22N after serial number 2226 Hold the function enable toggle switch to either side and move the jib toggle switch TS58 in the UP direction and check the voltage on the wht red 6 wire at the boom function proportional valve coil item CH 20V or more Continued on the next page 2 34 22 before serial number 153 and 234 22 before serial number 304 Move the jib toggle switch in the UP direction and check voltage at TB6 2 34 22 after serial number 152 and 234 22 after serial number 303 Hold the function enable toggle switch to either side and move the jib toggle switch in the UP direction and check voltage at TB6 oV Turn key switch to platform controls and pull both Emergency Stop buttons out to the ON position With boom function speed controller turned to 9 press down the foot switch and move the jib toggle switch Z 34 22 before serial number 1734 and Z 34 22N before serial number 2227 TS7 Z 34 22 after serial number 1733 and Z 34 22N after serial number 2226 TS8 in the uP direction Check voltage at TB6 20V or more Troubleshoot jib function toggle switch on ground controls OR repair open in wht red 6 wire circuit from toggle switch to TB6 OR consult Genie Industries Service Department Repair open in wht red 6 wire circuit from TB6 to boom function proportional valve coil OR repair open in brn
395. ved and installed or when new hoses or fittings are installed Hydraulic Hose and Fitting Torque Specifications SAE O ring Boss Port tube fitting Seal Lok hose end SAE Dash Installing SAE Dash 46 6 27 6 2 36 6 mnm 40 542 ed 3 45 9 84 8 mnm 4 542 gt 2 Stee 60 6 1627 9 aluminum 69 20 w w gea 24 44 40 190 jte tea 260 24 Aluminum Torque Procedure 1 Replace the O ring The O ring must be 3 Be sure that the face seal O ring is seated and replaced anytime the seal has been broken retained properly The O ring cannot be re used if the fitting or hose end has been tightened beyond finger tight 4 Position the tube and nut squarely on the face seal end of the fitting and tighten the nut finger tight The O rings used in the Parker a Seal Lok fittings and hose ends 5 Tighten the nut or fitting to the appropriate are custom size O rings They are torque per given size as shown in the table not standard SAE size O rings above They are available in the O ring 6 Operate all machine functions and inspect the nee kit hoses and fittings and related components to Genie part number 49612 be sure that there are no leaks 2 Lubricate the O ring before installation 2 4 Genie 7 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Prin
396. vot pin 25 Remove the primary boom pivot pin with a soft metal drift then carefully remove the boom from the machine AWARNING Crushing hazard The boom may become unbalanced and fall when it is removed from the machine If the overhead crane is not properly attached Part No 36540 Genie Z 34 22 amp Genie Z 34 22N Section 7 Repair Procedures First Edition Third Printing PRIMARY BOOM COMPONENTS How to Disassemble the Primary Boom 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 See 4 4 How to Hemove the Extension Cylinder 1 Remove the boom See 4 2 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 Pay careful attention to the location and amount of shims used with each wear pad 5 Carefully rotate the base end of the extension cylinder until the pin mounting bore is in a vertical position 6 Support the extension tube with an overhead crane at the platform end of the boom AWARNING Crushing hazard The boom tubes will fall when they are removed from the boom if they are not
397. wn Turn the key switch to platform control Part No 36540 Genie 2 34 22 amp Genie Z 34 22N 4 23 Section 4 Scheduled Maintenance Procedures First Edition Third Printing TABLE B PROCEDURES 6 Atthe platform controls pull out the Emergency Stop button to the position Result The flashing beacon should be and flashing 6 Move the lift drive switch to the position if equipped 7 Press down the foot switch Move the primary boom toggle switch to the pown position hold for a moment and then release it Move the secondary boom toggle switch to the Down position hold for a moment and then release it Move the jib boom toggle switch to the Down position hold for a moment and then release it Result The descent alarm should sound when each control toggle switch is held down 8 Move the lift drive switch to the prive position if equipped 9 Press down the foot switch Move the drive control handle off center hold for a moment and then release it Move the drive control handle off center in the opposite direction hold for amoment and then release it Result The travel alarm should sound when the drive control handle is moved off center in either direction B 17 Test the Turntable Rotation Stop The turntable is capable of rotating the boom 355 degrees and is stopped midpoint between the steering wheels by the rotation stop Detecting a rotation stop malfunction is essential
398. 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 Before cylinder removal is considered bleed the cylinder to be sure that there is no air in the closed loop See 2 2 How to Bleed the Slave Cylinder When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 7 Repair Procedures m H M ns M PRIMARY BOOM COMPONENTS 1 Removethe rearturntable cover 10 Use a soft metal drift to push the pin to one side only far enough to remove the cylinder The pin should remain in one side of the upper secondary boom and upper mid pivot 2 Raise the secondary boom until the master cylinder barrel end pivot pin is above the turntable counterweights 3 Raise the primary boom until the master AWARNING Crushing Hazard THUpper E oa secondary boom and the upper cylinder rod end pivot pin is accessible mid pivot will fall if the pivot pin is 4 Attach an overhead crane to the pivot end of completely removed the primary boom Do not lift it 11 Use the strap around the rod end lug to low
399. x out trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage 14 Raise the primary boom approximately 2 feet 0 6 m 15 Set the lo range on the drive circuit board Press down the foot switch and move the control handle all the way to the FoRwARD position Adjust the lo range trimpot on the drive circuit board to 2 4 to 2 7V DC Turn the lo range trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage 16 Lower the boom to the stowed position and remove the jack stands from under the drive chassis 17 Raise the primary boom approximately 2 feet 0 6 m 18 Create start and finish lines by marking two lines on the ground 40 feet 12 2 m apart Choose a reference point on the machine as a visual reference for use when crossing the start and finish lines 19 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 20 Continue at full speed and note the time when the reference point crosses the finish line 21 Adjust the lo range trimpot on the drive circuit board to achieve a 40 second drive speed time Turn the lo range trimpot clockwise to decrease the time or counterclockwise to increase the time 22 Lower the primary boom to the stowed position 23 Bring the machine to top drive speed before reaching the start line Begin timing when yo
400. xtend the primary boom past the limit switch LS1 and check voltage on Z 34 22 before serial number 153 and 234 22 before serial number 304 TB40 Z 34 22 from serial number 153 to 1733 and Z 34 22N from serial number 304 to 2226 TB52 Z 34 22 from serial number 153 to 1733 and Z 34 22N from serial number 304 to 2226 Raise the Repair or replace 152 OR check for mechanical restriction keeping LS2 activated Repair or replace LS1 OR check for mechanical restriction keeping LS1 activated Repair or replace LS4 OR check for mechanical restriction keeping LS4 activated Chart 35 Adjust drive controller OR repair or replace drive controller OR consult Genie Industries Service Department Adjust drive controller OR repair or replace drive controller OR consult Genie Industries Service Department secondary boom above the limit switch LS4 and check voltage on TB40 on the boom when the primary boom is raised Be sure the secondary boom drive limit switch is being activated by the secondary boom compression arm when the secondary boom is raised Adjust drive controller OR repair or replace drive controller OR consult Genie Industries Service Department Part No 36540 Genie Z 34 22 amp Genie Z 34 22N 5 125 Section 5 Troubleshooting Flow Charts First Edition Third Printing Chart 36 Machine Drives At Full Speed With Platform Raised Or Extended Z 34 22 aft
401. y connected and fully charged Turn key switch to platform controls and pull both Emergency Stop buttons out to the ON position Check voltage on R terminal on the drive controller Check voltage on TB40 Check voltage on TB23 Repair open in the wht 2 wire circuit with diode from the platform Emergency Stop button to TB23 OR replace the diode Adjust the drive controller See Repair Section OR repair or replace drive controller OR consult Genie Industries Service Department Repair open in org 1 wire circuit from TB40 to R terminal on the drive controller Repair open in wire circuit from 2 34 22 before serial number 153 and Z34 22N before serial number 304 TB23 to LS1 to TB49 to LS2 to TB40 2 34 22 from serial number 153 to 1733 and Z 34 22N from serial number 304 to 2226 TB23 to LS1 to TB49 to LS2 to 52 to LS4 to 40 5 122 Genie Z 34 22 amp Genie Z 34 22N Part No 36540 First Edition Third Printing Section 5 Troubleshooting Flow Charts Machine Will Not Drive At Full Speed Z 34 22 after serial number 1733 and Z 34 22N after serial number 2226 Be sure all other functions operate normally Be sure the boom is in the stowed position with the primary boom fully retracted Be sure the primary boom extension limit switch LS1 is being activated when the primary boom is retracted Be sure the primary boom and secondary boom limi

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