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Service and Repair Manual Serial Number Range Z-34/22 from Z3414-9686 This manual includes: Repair procedures Bi-Energy Power Fault Codes Electrical and Hydraulic Schematics For detailed maintenance procedures, refer to the appropriate Maintenance Manual for your machine. Part No. 1268515 Rev A...
Reference Examples: Electronic Version Section – Repair Procedure, 4-2 Click on any content or procedure in the Table of Contents to view Section – Fault Codes, All charts the update. Section – Schematics, Legends and schematics Part No. 1268515 Z-34/22 Bi-Energy...
Service and Repair Manual September 2015 Introduction Serial Number Legend 1 Model 2 Model year 3 Sequence number 4 Serial number (stamped on chassis) 5 Serial label Z-34/22 Bi-Energy Part No. 1268515...
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. 1268515 Z-34/22 Bi-Energy...
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Be aware of potential crushing hazards such as moving parts, free swinging or unsecured components when lifting or placing loads. Always wear approved steel-toed shoes. Z-34/22 Bi-Energy Part No. 1268515...
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3-2 Jib Boom Bell Crank ..................23 How to Remove the Jib Boom Bell Crank ............23 3-3 Jib Boom Lift Cylinder ..................23 How to Remove the Jib Boom Lift Cylinder ............ 23 viii Z-34/22 Bi-Energy Part No. 1268515...
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6-2 RPM Adjustment .................... 39 6-3 Engine Drive Pulley ..................39 How to Remove the Engine Drive Pulley ............39 How to Install the Engine Drive Pulley ............40 6-4 Coolant Temperature and Oil Pressure Switches .......... 41 Part No. 1268515 Z-34/22 Bi-Energy...
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9-3 Jib Boom / Platform Rotate Manifold Components........54 9-4 Valve Coils ..................... 55 How to Test a Coil ..................55 Valve Coil Resistance Specification ............... 55 How to Test a Coil Diode ................56 Z-34/22 Bi-Energy Part No. 1268515...
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How to Install the Hub and Bearings ............... 61 12-2 Steer Cylinder ....................61 Non-steer Axle Components ................63 13-1 Drive Motor ....................63 13-2 Drive Hubs....................63 Motor Controller ....................64 14-1 Motor Controller ................... 64 Part No. 1268515 Z-34/22 Bi-Energy...
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LVI / BCI Option Wiring Diagram, from serial number 4800 to 5426 ....104 LVI / BCI Option Wiring Diagram, from serial number 5427 ......105 Engine Wiring Diagram ..................108 Hydraulic Schematic ..................109 Z-34/22 Bi-Energy Part No. 1268515...
Drive hub oil type: SAE 90 multipurpose hypoid gear oil Operator's Manual. API service classification GL5 Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice or obligation. Part No. 1268515 Z-34/22 Bi-Energy...
Hydraulic fluids may be incompatible due to the Hydraulic Fluid Specifications differences in base additive Genie specifications require hydraulic oils which are chemistry. When incompatible designed to give maximum protection to hydraulic fluids are mixed, insoluble systems, have the ability to perform over a wide...
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Maximum continuous operating 124°F / 51°C temperature Note: Use of Chevron 5606A hydraulic fluid, or equivalent, is required when ambient temperatures are consistently below 0°F / -17°C unless an oil heating system is used. Part No. 1268515 Z-34/22 Bi-Energy...
Oil capacity (including filter) 2.6 quarts Reserve capacity @ 25A rate 125 minutes 2.5 liters Extreme operating temperatures may require the use of alternative engine oils. For oil requirements, refer to the Engine Operator Handbook on your machine. Z-34/22 Bi-Energy Part No. 1268515...
Your machine is equipped with Parker Seal-Lok™ SAE Dash Size Torque ORFS or 37° JIC fittings and hose ends. Genie specifications require that fittings and hose ends 14 ft-lbs / 19 Nm be torqued to specification when they are removed 23 ft-lbs / 31.2 Nm...
O-rings. They are not 1 hex nut standard size O-rings. They are available in the 2 reference mark O-ring field service kit (Genie part number 49612). 3 body hex fitting Lubricate the O-ring before installation. Working clockwise on the body hex fitting,...
Be sure that all necessary tools and parts are available and ready for use. Use only Genie approved replacement parts. Read each procedure completely and adhere to the instructions. Attempting shortcuts may produce hazardous conditions.
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Indicates that a specific result is expected after performing a series of steps. Indicates that an incorrect result has occurred after performing a series of steps. Z-34/22 Bi-Energy Part No. 1268515...
Emergency Stop button to the needed on the drive joystick controller. For further on position at both the ground and platform information or assistance, contact the Genie controls. Product Support. Open the platform control box lid and locate the boom function speed controller.
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Start a timer and simultaneously press down the foot switch and move the primary boom toggle switch in the down direction. Note how long it takes to reach 0.65A. Z-34/22 Bi-Energy Part No. 1268515...
Test Desired result red to black no continuity (infinite Ω) red to white no continuity black to white continuity (zero Ω) Part No. 1268515 Z-34/22 Bi-Energy...
Connect the leads of an ohmmeter to the switch terminals in the following combinations listed below to check for continuity. Left Center Right SPDT DPDT Note: Single pole double throw (SPDT), Double pole double throw (DPDT) Z-34/22 Bi-Energy Part No. 1268515...
Lower the Move the platform level toggle switch up and boom until the platform is resting on the down through two platform leveling cycles to blocks. remove any air that might be in the system. Part No. 1268515 Z-34/22 Bi-Energy...
Do not apply any lifting pressure. 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. Z-34/22 Bi-Energy Part No. 1268515...
Close the bleed screw. Crushing hazard. Keep clear of the platform during rotation. Clean up any hydraulic oil that may have spilled. Rotate the platform fully in both directions and inspect the bleed screws for leaks. Part No. 1268515 Z-34/22 Bi-Energy...
Note: The platform will need to be moved up and down and allowed to settle between adjustments. Z-34/22 Bi-Energy Part No. 1268515...
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Result: The alarm should sound. The platform overload indicator light should be flashing at both the ground and platform controls. Note: There may be an approximate 2 second delay before the overload indicator light turns on and the alarm sounds. Part No. 1268515 Z-34/22 Bi-Energy...
Crushing hazard. The jib boom lift cylinder may become unbalanced and fall when it is removed from the machine if it is not properly supported by the overhead crane. Z-34/22 Bi-Energy Part No. 1268515...
Do not Crushing hazard. The jib boom remove the pin. bellcrank may become unbalanced and fall if it is not properly supported when it is removed from the machine. Part No. 1268515 Z-34/22 Bi-Energy...
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Crushing hazard. The jib boom lift cylinder may become unbalanced and fall when it is removed from the machine if it is not properly supported by the overhead crane. Z-34/22 Bi-Energy Part No. 1268515...
Note: Always maintain squareness between the outer and inner boom tubes. Note: A 7 link repair section of cable track is available through the Genie Service Parts How to R emove the Primary Boom How to Remove the Primary Department.
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Do not allow oil to squirt or spray. 16 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. Z-34/22 Bi-Energy Part No. 1268515...
Crushing hazard. If the overhead crane is not properly attached, the boom could become unbalanced and fall when it is removed from the machine. Part No. 1268515 Z-34/22 Bi-Energy...
Attach a lifting strap from an overhead crane to the primary boom for support. Do not apply any lifting pressure. Place a block of wood across the upper secondary boom to support the cylinder when the rod-end pivot pin is removed. Z-34/22 Bi-Energy Part No. 1268515...
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19 Carefully remove the cylinder from the 12 Swing the compression arm up out of the way machine. and secure it from moving. Part No. 1268515 Z-34/22 Bi-Energy...
Remove the external snap rings from the extension cylinder rod-end pivot pins. Use a soft metal drift to remove the pins. Remove the rear turntable cover. Raise the secondary boom until the master cylinder rod-end pivot pin is accessible. Z-34/22 Bi-Energy Part No. 1268515...
Specifications, Hydraulic Hose and Fitting Torque Specifications. Note: Before cylinder removal is considered, bleed the cylinder to be sure that there is no air in the closed loop. Refer to Repair Procedure, How to Bleed the Slave Cylinder. Part No. 1268515 Z-34/22 Bi-Energy...
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Tie a strap around the lug on the rod end of the master cylinder and secure the strap to the primary boom. Note: The strap will be used to lower the cylinder out of the upper pivot. Z-34/22 Bi-Energy Part No. 1268515...
Service and Repair Manual Secondary Boom Components Second ar y Boo m Comp onent s Secondary Boom components lower secondary boom upper pivot turntable pivot upper compression arm lower compression arm mid-pivot upper secondary boom compression link Part No. 1268515 Z-34/22 Bi-Energy...
Do not disconnect the wiring. 15 Attach a strap from an overhead crane to the pivot end of the primary boom. Z-34/22 Bi-Energy Part No. 1268515...
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Use a soft metal drift to remove the pin. 31 Attach the strap from an overhead crane to the upper secondary boom. Part No. 1268515 Z-34/22 Bi-Energy...
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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. Z-34/22 Bi-Energy Part No. 1268515...
Raise the primary boom to full height. Do not extend it. Attach the strap from an overhead crane to the lug on the rod end of the secondary boom lift cylinder. Part No. 1268515 Z-34/22 Bi-Energy...
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Crushing hazard. The secondary boom lift cylinder could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane. Z-34/22 Bi-Energy Part No. 1268515...
Kubota Z482-E. How to Remove the Engine Drive Pulley Kubota Z482-E3B Operator's Manual Genie part number 139420 Remove the engine pivot plate latch retainer. 6-2 R PM Adj ustm ent Open the engine pivot plate latch and swing...
Loosen the set screw on the pulley bushing, then slide the pulley bushing off of the generator shaft. 1 gap 2 shaft 3 set screw 4 engine drive pulley 5 engine drive pulley bolt 6 shaft bushing 7 woodruff key Z-34/22 Bi-Energy Part No. 1268515...
Loosen the tension adjustment bolt on the 1 engine pulley generator. 2 generator belts Pull the generator away from the machine and 3 generator pulley tighten the adjustment bolt. Belt deflection, 0.25 inch maximum allowable 6.5 mm Part No. 1268515 Z-34/22 Bi-Energy...
Remove all rings, Note: The maximum range of motion of the watches and other jewelry. potentiometer on the voltage regulator is 280° and the maximum allowed torque is 5 oz-in / 0.035 Nm. Z-34/22 Bi-Energy Part No. 1268515...
11 Remove the nuts on those 3 wires from the negative rectifier assembly, then remove the wires. Note: Do not remove the spacers from the underneath the wires on the negative rectifier assembly. Part No. 1268515 Z-34/22 Bi-Energy...
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How to Adjust the Generator Belts. 22 Adjust the voltage regulator. See How to Adjust the Voltage Regulator. Component damage hazard. The voltage regulator and/or generator may become damaged if the voltage regulator is not properly adjusted after replacement Z-34/22 Bi-Energy Part No. 1268515...
Result: The pressure fails to reach 2800 psi /193 bar, the pump is faulty and will need to be serviced or replaced. Remove the pressure gauge and install the hydraulic hose. How to R emove the Auxiliary Pum p Part No. 1268515 Z-34/22 Bi-Energy...
Hydraulic pressure in excess of 3000 psi / 206 bar may result in severe component damage. Remove the pressure gauge and install the hydraulic hose. How to R emovet the F unc tion Pum p Z-34/22 Bi-Energy Part No. 1268515...
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Repeat steps 2 and 3 to confirm the relief Repeat steps 2 through 4 and recheck relief valve pressure setting. valve pressure. Remove the pressure gauge. Remove the pressure gauge. Z-34/22 Bi-Energy Part No. 1268515...
Repeat steps 2 through 4 and recheck relief specified. valve pressure. Repeat steps 2 and 3 to confirm the relief Remove the pressure gauge. valve pressure setting. Remove the pressure gauge. Part No. 1268515 Z-34/22 Bi-Energy...
Result: The resistance should be within specification, plus or minus 30%. Result: If the resistance is not within specification, plus or minus 30%, replace the coil. Part No. 1268515 Z-34/22 Bi-Energy...
Note: The multimeter, when set to read DC current, Resistor, 10Ω should be capable of reading up to 800 mA. Genie part number 27287 Connect the negative lead to the other Note: The battery should read 9V DC or more terminal on the coil.
Component damage hazard. Do condition. not overtighten the fuel tank mounting fasteners. Note: Clean the fuel tank and inspect for cracks and other damage before installing. Part No. 1268515 Z-34/22 Bi-Energy...
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Remove the hydraulic tank mounting fasteners. Remove the hydraulic tank from the machine. Crushing hazard. The hydraulic tank could become unbalanced and fall if not properly supported when removed from the machine. Z-34/22 Bi-Energy Part No. 1268515...
Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. Remove the turntable rotation motor mounting bolts. Remove the motor from the machine. Part No. 1268515 Z-34/22 Bi-Energy...
Block the non-steer wheels, and then center a lifting jack under the steering axle. Raise the machine 6 inches / 15 cm and place blocks under the drive chassis for support. Remove the lug nuts, then the tire and wheel assembly. Z-34/22 Bi-Energy Part No. 1268515...
Note: Always use a new cotter pin when installing a castle nut. 11 Install the dust cap, then the tire and wheel assembly. Torque the wheel lug nuts to specification. Refer to Specifications, Machine Torque Specifications. 12- 2 Steer Cyli nder Part No. 1268515 Z-34/22 Bi-Energy...
Do not allow oil to squirt or spray. Remove the pin retaining fastener, then remove the clevis pin from each end of the steer cylinder. Remove the steer cylinder. Z-34/22 Bi-Energy Part No. 1268515...
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. Part No. 1268515 Z-34/22 Bi-Energy...
There are no adjustments needed on Forward Bias: the drive joystick controller. For further information Test Desired result or assistance, consult the Genie Industries Service Positive Lead Negative Lead Department. 0.4 to 0.45 0.4 to 0.45 How to Test the Motor Controller 0.45 to 0.5...
• All external AC power supply disconnected from the machine • Boom in the stowed position • Turntable secured with the turntable rotation lock • Welder disconnected from the machine (if equipped with the weld cable to platform option) Part No. 1268515 Z-34/22 Bi-Energy...
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Fault Codes Fault Codes Note: Additional troubleshooting of the fault codes may by accomplished by using the hand-held pendant motor controller programmer (Genie part number 56303). For authorized service personnel only: Note: When using the hand-held pendant motor controller programmer, the M1 MAX SPEED needs to be set to 33.
OR test the motor controller. See Repair Section. ARM SENSOR Machine will not drive. Defective motor Replace the motor controller. controller. FLD SENSOR Machine will not drive. Defective motor Replace the motor controller. controller. Part No. 1268515 Z-34/22 Bi-Energy...
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Possible Causes Solution Diagnostic Display THROTTLE FAULT 1 Machine will not drive. Open in wht/red wire Consult Genie Product #32 at pin 14 or Support. red/wht wire #29 at pin 16 on the motor controller going from drive joystick to pins...
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Programmer Condition Possible Causes Solution Diagnostic Display MISSING Machine will not drive. Motor controller does Consult Genie Product CONTACTOR not detect the main Support. contactor PR1 or brake release relay CR5. MAIN CONT DNC Machine will not drive. Main contactor PR1 or...
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Service and Repair Manual September 2015 This page intentionally left blank. Z-34/22 Bi-Energy Part No. 1268515...
Read, understand and obey the safety rules and operating instructions in the appropriate operator's manual on your machine. Be sure that all necessary tools and test equipment are available and ready for use. Part No. 1268515 Z-34/22 Bi-Energy...
Gauge sending unit open normally closed Oil temperature switch Coolant temperature Oil pressure switch Control relay contact Diode starting aid, glow normally open switch - normally open normally closed normally open plug or flame ignitor Z-34/22 Bi-Energy Part No. 1268515...
3 way shuttle valve valve Solenoid operated Solenoid operated Counterbalance valve with 3 position, 4 way 2 position, 2 way solenoid 3 position, 4 way directional pressure and pilot ratio proportional directional valve valve valve Part No. 1268515 Z-34/22 Bi-Energy...
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September 2015 Service and Repair Manual Electrical Schematic - from serial number 4800 to 5426 (ANSI / CSA)
Service and Repair Manual September 2015 Elec trical Schem atic - from serial number 4800 to 5426 (AN SI / C SA) Electrical Schematic - from serial number 4800 to 5426 (ANSI / CSA) Z-34/22 Bi-Energy Part No. 1268515...
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September 2015 Service and Repair Manual Electrical Schematic - from serial number 4800 to 5426 (ANSI / CSA) Part No. 1268515 Z-34/22 Bi-Energy...
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Service and Repair Manual September 2015 Electrical Schematic - from serial number 4800 to 5426 (ANSI / CSA)
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September 2015 Service and Repair Manual Electrical Schematic - from serial number 4800 to 5426 (CE)
Service and Repair Manual September 2015 Elec trical Schem atic - from serial number 4800 to 5426 (CE) Electrical Schematic - from serial number 4800 to 5426 (CE) Z-34/22 Bi-Energy Part No. 1268515...
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September 2015 Service and Repair Manual Electrical Schematic - from serial number 4800 to 5426 (CE) Part No. 1268515 Z-34/22 Bi-Energy...
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Service and Repair Manual September 2015 Electrical Schematic - from serial number 4800 to 5426 (CE)
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September 2015 Service and Repair Manual Electrical Schematic - from serial number 5427 (ANSI / CSA)
Service and Repair Manual September 2015 Elec trical Schem atic - from serial number 5427 (AN SI / C SA) Electrical Schematic - from serial number 5427 (ANSI / CSA) Z-34/22 Bi-Energy Part No. 1268515...
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September 2015 Service and Repair Manual Electrical Schematic - from serial number 5427 (ANSI / CSA) Part No. 1268515 Z-34/22 Bi-Energy...
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Service and Repair Manual September 2015 Electrical Schematic - from serial number 5427 (ANSI / CSA)
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September 2015 Service and Repair Manual Electrical Schematic - from serial number 5427 (CE)
Service and Repair Manual September 2015 Elec trical Schem atic - from serial number 5427 (CE) Electrical Schematic - from serial number 5427 (CE) Z-34/22 Bi-Energy Part No. 1268515...
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September 2015 Service and Repair Manual Electrical Schematic - from serial number 5427 (CE) Part No. 1268515 Z-34/22 Bi-Energy...
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Service and Repair Manual September 2015 Electrical Schematic - from serial number 5427 (CE)
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September 2015 Service and Repair Manual Ground Control Box Switch Panel Wiring Diagram...
Service and Repair Manual September 2015 Ground C ontrol Box Switch Panel Wiring Di agr am Ground Control Box Switch Panel Wiring Diagram Z-34/22 Bi-Energy Part No. 1268515...
September 2015 Service and Repair Manual Ground C ontrol Box T erminal Strip Wiring Di agr am Ground Control Box Terminal Strip Wiring Diagram Part No. 1268515 Z-34/22 Bi-Energy...
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Service and Repair Manual September 2015 Ground Control Box Terminal Strip Wiring Diagram...
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September 2015 Service and Repair Manual Platform Control Box Wiring Diagram...
Service and Repair Manual September 2015 Platform C ontrol Box Wiring Di agr am Platform Control Box Wiring Diagram Z-34/22 Bi-Energy Part No. 1268515...
September 2015 Service and Repair Manual Manifold and Limit Swi tch Wiring Diagram Manifold and Limit Switch Wiring Diagram Part No. 1268515 Z-34/22 Bi-Energy...
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Service and Repair Manual September 2015 Manifold and Limit Switch Wiring Diagram...
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September 2015 Service and Repair Manual LVI / BCI Option Wiring Diagram, from serial number 4800 to 5426...
Service and Repair Manual September 2015 LVI / BCI Opti on Wiring Di agram, from seri al num ber 4800 to 5426 LVI / BCI Option Wiring Diagram, from serial number 4800 to 5426 Z-34/22 Bi-Energy Part No. 1268515...
September 2015 Service and Repair Manual LVI / BCI Opti on Wiring Di agram, from seri al num ber 5427 LVI / BCI Option Wiring Diagram, from serial number 5427 Part No. 1268515 Z-34/22 Bi-Energy...
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Service and Repair Manual September 2015 LVI / BCI Option Wiring Diagram, from serial number 5427...
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September 2015 Service and Repair Manual Engine Wiring Diagram...
September 2015 Service and Repair Manual Hydraulic Schem atic Hydraulic Schematic Part No. 1268515 Z-34/22 Bi-Energy...
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Service and Repair Manual September 2015 Hydraulic Schematic Z-34/22 Bi-Energy Part No. 1268515 Servic e and R epair M anual Sept emb er 2015...