Genie Z-34/22 Service Manual
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Genie Z-34/22 Service Manual

Bi-energy power
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Download this manual See also: Operator's Manual
Service Manual
Z-34/22
Bi-Energy Power
Serial Number Range
from Z3406-4800 to
Z3414-9685
Part No. 139234
Rev B1
April 2016

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Summary of Contents for Genie Z-34/22

  • Page 1 Service Manual Serial Number Range Z-34/22 from Z3406-4800 to Z3414-9685 Bi-Energy Power Part No. 139234 Rev B1 April 2016...

  • Page 2: Find A Manual For This Model

    Copyright © 1997 by Terex Corporation 139234 Rev B1, April 2016 Third Edition, First Printing Genie is a registered trademark of Terex South Dakota, Inc. in the U.S.A. and many other countries. “Z” is a trademark of Terex South Dakota, Inc.

  • Page 3: Revision History

    Section – Maintenance, B-3 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. 139234 Z-34/22 Bi-Energy...

  • Page 4: Serial Number Legend

    Service Manual April 2016 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. 139234...

  • Page 5: Safety Rules

     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. 139234 Z-34/22 Bi-Energy...
  • Page 6 Be sure that your workshop or work area warrants it. is properly ventilated and well lit. 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. 139234...

  • Page 7: Table Of Contents

    Pre-Delivery Preparation Report ................14 Maintenance Inspection Report................16 Maintenance Inspection Report................17 Checklist A Procedures ..................18 A-1 Inspect the Manuals and Decals..............18 A-2 Perform Pre-operation Inspection ..............19 A-3 Perform Function Tests ................. 19 Part No. 139234 Z-34/22 Bi-Energy...
  • Page 8 B-16 Check the Electrical Contactors ..............38 B-17 Inspect the Fuel and Hydraulic Tank Cap Venting Systems ....... 38 B-18 Perform Hydraulic Oil Analysis ..............39 B-19 Test the Emergency Power System ............40 B-20 Perform Engine Maintenance ..............41 viii Z-34/22 Bi-Energy Part No. 139234...
  • Page 9 Platform Controls ....................57 1-1 Controllers ...................... 57 Boom Function Speed Controller Adjustments ..........57 1-2 Diodes ......................59 1-3 Foot Switch..................... 59 1-4 Toggle Switches ..................... 60 How to Test a Toggle Switch ................60 Part No. 139234 Z-34/22 Bi-Energy...
  • Page 10 How to Remove the Primary Boom Lift Cylinder ..........72 4-4 Primary Boom Extension Cylinder ..............74 How to Remove the Primary Boom Extension Cylinder ........74 4-5 Platform Leveling Master Cylinder ..............75 How to Remove the Platform Leveling Master Cylinder ......... 75 Z-34/22 Bi-Energy Part No. 139234...
  • Page 11 How to Test the Auxiliary Pump ..............91 How to Remove the Auxiliary Pump..............91 8-2 Function Pump ....................92 How to Test the Function Pump ..............92 How to Removet the Function Pump .............. 92 Part No. 139234 Z-34/22 Bi-Energy...
  • Page 12 How to Install the Hub and Bearings ............. 105 12-2 Steer Cylinder ..................... 105 Non-steer Axle Components ................106 13-1 Drive Motor ....................106 13-2 Drive Hubs ....................106 Motor Controller ....................108 14-1 Motor Controller ..................108 Z-34/22 Bi-Energy Part No. 139234...
  • Page 13 LVI / BCI Option Wiring Diagram, from serial number 4800 to 5426 ....166 LVI / BCI Option Wiring Diagram, from serial number 5427 ......167 Engine Wiring Diagram ..................170 Hydraulic Schematic ................... 171 Part No. 139234 Z-34/22 Bi-Energy xiii...

  • Page 14: Specifications

    Drive hubs 17 fl oz Platform level down 10 to 20 seconds 503 cc For operational specifications, refer to the Drive hub oil type: SAE 90 multipurpose hypoid gear oil Operator's Manual. API service classification GL5 Part No. 139234 Z-34/22 Bi-Energy...

  • Page 15: Hydraulic Specification

    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...
  • Page 16 Continued use of Chevron 5606A Pour point -81°F / -63°C hydraulic fluid, or equivalent, Maximum continuous operating 189°F / 87°C when ambient temperatures are temperature consistently above 32°F / 0°C may result in component damage Part No. 139234 Z-34/22 Bi-Energy...

  • Page 17: Hydraulic Component Specifications

    110.3 bar Primary boom extend relief valve 1800 psi pressure 124 bar Turntable rotate relief valve 1100 psi pressures 75.8 bar Hydraulic Filters Hydraulic tank return filter 10 micron with 25 psi / 1.7 bar bypass Z-34/22 Bi-Energy Part No. 139234...

  • Page 18: Machine Torque Specifications

    4 ft / 1.5 m platform 99 lbs 45 kg 5 ft / 2.4 m platform 105 lbs 48 kg Battery 6volt (wet) 88 lbs 48 kg Battery 6 volt (maintenance free) 105 lbs 48 kg Part No. 139234 Z-34/22 Bi-Energy...

  • Page 19: Kubota Z482-E Engine Specifications

    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. 139234...

  • Page 20: Generator Specifications

    108-122 Nm Engine pulley retaining bolts 108 in-lbs 12.2 Nm #10 screw 25 in-lbs 2.8 Nm #10 nut 25 in-lbs 2.8 Nm #4 nut 8-10 in-lbs 0.9-1.1 Nm Voltage regulator mounting fasteners 25 in-lbs 2.8 Nm Part No. 139234 Z-34/22 Bi-Energy...

  • Page 21: Hydraulic Hose And Fitting Torque Specifications

    SAE O-ring Boss Port (tube fitting - installed into Aluminum) Your machine is equipped with Parker Seal-Lok™ (all types) ORFS or 37° JIC fittings and hose ends. Genie SAE Dash Size Torque specifications require that fittings and hose ends be...

  • Page 22: Torque Procedure

    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,...

  • Page 23: Sae And Metric Fasteners Torque Charts

    Service Manual April 2016 Specifications Z-34/22 Bi-Energy Part No. 139234...

  • Page 24: Scheduled Maintenance Procedures

     Repair any machine damage or malfunction before operating the machine.  Use only Genie approved replacement parts.  Machines that have been out of service for a period longer than 3 months must complete the quarterly inspection.
  • Page 25 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. 139234...
  • Page 26 Make copies of the Maintenance Inspection Report to use for each inspection. Maintain completed forms for a minimum of 4 years or in compliance with your employer, jobsite and governmental regulations and requirements. Part No. 139234 Z-34/22 Bi-Energy...

  • Page 27: Pre-Delivery Preparation Report

    Service Manual April 2016 Pre-Delivery Preparation Report Fundamentals Instructions It is the responsibility of the owner or dealer to Use the operator’s manual on your machine. perform the Pre-delivery Preparation. The Pre-delivery Preparation consists of The Pre-delivery Preparation is performed prior to completing the Pre-operation Inspection, the each delivery.
  • Page 28 April 2016 Service Manual This page intentionally left blank. Part No. 139234 Z-34/22 Bi-Energy...

  • Page 29: Maintenance Inspection Report

    • If any inspection receives an "N," tag and remove the machine from service, repair and re-inspect it. After repair, place a check in the "R" box. Legend Y = yes, acceptable N = no, remove from service R = repaired Z-34/22 Bi-Energy Part No. 139234...

  • Page 30: Maintenance Inspection Report

    • If any inspection receives an "N," tag and remove the machine from service, repair and re-inspect it. After repair, place a check in the "R" box. Legend Y = yes, acceptable N = no, remove from service R = repaired Part No. 139234 Z-34/22 Bi-Energy...

  • Page 31: Checklist A Procedures

    Carefully and thoroughly Inspect the Manuals and Decals inspect all decals on the machine for legibility and damage. Genie specifications require that this procedure be performed every 8 hours or daily, whichever comes Result: The machine is equipped with all first.

  • Page 32: Perform Pre-Operation Inspection

    Service Manual Checklist A Procedures Perform Pre-operation Inspection Perform Function Tests Genie specifications require that this procedure be Genie specifications require that this procedure be performed every 8 hours or daily, whichever comes performed every 8 hours or daily, whichever comes first.

  • Page 33: Perform Engine Maintenance

    Operator and Maintenance manuals. running. Remove the key to secure from operation. Kubota - Z482-E Bodily injury hazard. Beware of Genie part number 52958 hot engine components. Contact with hot engine components may cause severe burns.
  • Page 34 Engine Drive Pulley to adjust the pulley alignment. Pulley alignment, maximum offset 0.0625 inch 1.58 mm Inspect the generator belts for: • Cracking • Glazing • Separation • Breaks Replace both belts if any damage is found. Part No. 139234 Z-34/22 Bi-Energy...

  • Page 35: Perform 30 Day Service

    Required maintenance procedures and additional Torque engine information are available in the following Operator and Maintenance manuals. • D-2 Check the Turntable Rotation Bearing Bolts Kubota - Z482-E • D-6 Replace the Hydraulic Filters Genie part number 52958 Z-34/22 Bi-Energy Part No. 139234...

  • Page 36: Perform Engine Maintenance

    Required maintenance procedures and additional Operator and Maintenance manuals. engine information are available in the following Operator and Maintenance manuals. Kubota - Z482-E Genie part number 52958 Kubota - Z482-E Genie part number 52958 Part No. 139234...

  • Page 37: Grease The Turntable Rotation Bearing And Worm Drive Gear

    Before serial number 5204: Remove the safety chock. Lower the boom to the stowed Genie specifications require that this procedure be position. performed every 100 hours of operation. Locate the grease fitting on the worm drive Frequent application of lubrication to the turntable housing.

  • Page 38: Replace The Drive Hub Oil

    Remove the plugs and drain the oil into a suitable container. Drive the machine until one of the two plugs is at the highest point. 1 drive hub plugs Part No. 139234 Z-34/22 Bi-Energy...

  • Page 39: Perform Engine Maintenance

    • Radiator hoses and clamps - check • Intake air line - check Required maintenance procedures and additional engine information are available in the following Operator and Maintenance manuals. Kubota - Z482-E Genie part number 52958 Z-34/22 Bi-Energy Part No. 139234...

  • Page 40: Checklist B Procedures

    Service Manual Checklist B Procedures Inspect the Battery Check the Exhaust System Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever Maintaining the exhaust system is essential to comes first.
  • Page 41 10 Check the battery acid level. If needed, replenish with distilled water to 1/8 inch / 3 mm below the bottom of the battery fill tube. Do not overfill. 11 Install the vent caps and neutralize any electrolyte that may have spilled. Z-34/22 Bi-Energy Part No. 139234...

  • Page 42: Inspect The Electrical Wiring

    Inspect the turntable area for burnt, chafed and pinched cables. Genie specifications require that this procedure be Lower the secondary boom to the stowed performed every 250 hours or quarterly, whichever position and turn the engine off.

  • Page 43: Inspect The Tires, Wheels And Lug Nut Torque

    Inspect the Tires, Wheels and Confirm the Proper Brake Lug Nut Torque Configuration Genie specifications require that this procedure be Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever performed every 250 hours or quarterly, whichever comes first.

  • Page 44: Check The Drive Hub Oil Level And Fastener Torque

    Checklist B Procedures Check the Oil Level in the Drive Check the Glow Plugs Hubs Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever Genie specifications require that this procedure be comes first. performed every 250 hours or quarterly, whichever comes first.

  • Page 45: Check And Adjust The Engine Rpm

    Tighten the lock nut and recheck the rpm. Kubota Z482-E Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Maintaining the engine rpm at the proper setting for both low and high idle is essential to good engine performance and service life.

  • Page 46: Test The Ground Control Override

    Checklist B Procedures B-10 Test the Ground Control Override Test the Platform Self-leveling Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever A properly functioning ground control override is comes first.

  • Page 47: Test The Engine Idle Select

    Move the engine idle control switch to high idle (rabbit symbol). Operation Result: The engine should change to high idle. Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever Move the engine idle control switch to low idle comes first.

  • Page 48: Test The Drive Brakes

    B-13 Test the Drive Brakes Test the Drive Speed – Stowed Position Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever Genie specifications require that this procedure be comes first. performed every 250 hours or quarterly, whichever comes first.

  • Page 49: Test The Drive Speed - Raised Or Extended Position

    Bring the machine to top drive speed before reaching the start line. Begin timing when your Genie specifications require that this procedure be reference point on the machine crosses the performed every 250 hours or quarterly, whichever start line.

  • Page 50: Test The Alarm Package (If Equipped)

    Result: The descent alarm should sound when Genie specifications require that this procedure be the switch is held down. performed every 250 hours or quarterly, whichever comes first.

  • Page 51: Check The Electrical Contactors

    Inspect the Fuel and Hydraulic Tank Cap Venting Systems Note: Genie specifications require that this procedure be performed every 250 hours or Genie specifications require that this procedure be quarterly, whichever comes first. performed every 250 hours or quarterly, whichever comes first.

  • Page 52: Perform Hydraulic Oil Analysis

    Repeat this procedure beginning with step 2. Install the fuel tank cap onto the fuel tank. Genie specifications require that this procedure be Remove the breather cap from the hydraulic performed every 250 hours or quarterly, whichever tank.

  • Page 53: Test The Emergency Power System

    Press down on the foot switch and simultaneously hold the emergency power switch on and activate each boom function. Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever Note: To conserve battery power, test each comes first.

  • Page 54: Perform Engine Maintenance

    Engine specifications require that this procedure be performed every 400 hours. • Fuel filter - replace Required maintenance procedures and additional engine information are available in the following Operator and Maintenance manuals. Kubota - Z482-E Genie part number 52958 Part No. 139234 Z-34/22 Bi-Energy...

  • Page 55: Checklist C Procedures

    Test the Platform Overload Grease the Platform Overload System - (if equipped) Mechanism (if equipped) Genie specifications require that this procedure be Genie specifications require that this procedure be performed every 500 hours or six months, performed every 500 hours or six months, whichever comes first OR when the machine fails whichever comes first.
  • Page 56 Note: There may be a 2 second delay before the overload indicator lights flash and the alarm sounds. Part No. 139234 Z-34/22 Bi-Energy...

  • Page 57: Perform Engine Maintenance

    • Cleaning of water jacket (radiator interior) Operator and Maintenance manuals. • Removal of sediment in fuel tank Kubota - Z482-E • Recharging battery Genie part number 52958 • Damage in electric wiring and loose connections - check Required maintenance procedures and additional engine information are available in the following Operator and Maintenance manuals.

  • Page 58: Checklist D Procedures

    Checklist D Procedures Check the Turntable Rotation Check the Boom Wear Pads Bearing Bolts Genie specifications require that this procedure be performed every 1000 hours or annually, Genie specifications require that this procedure be whichever comes first. performed every 1000 hours or annually, whichever comes first.

  • Page 59: Inspect For Turntable Bearing Wear

    Access the turntable bearing bolts through the access hole on the side of the chassis. Confirm that each turntable mounting bolt is Genie specifications require that this procedure be torqued in sequence to specification. Refer to performed every 1000 hours or annually, Specifications, Machine Torque whichever comes first.
  • Page 60 4 turntable rotation bearing Adjust the dial indicator needle to the "zero" position. Lower the secondary boom to the stowed position and lower the primary boom to a horizontal position. Fully extend the primary boom. Part No. 139234 Z-34/22 Bi-Energy...

  • Page 61: Check The Free-Wheel Configuration

    Check the Free-wheel wheel hub. Configuration Genie specifications require that this procedure be performed every 1000 hours or annually, whichever comes first. Proper use of the free-wheel configuration is 1 brake disengaged position essential to safe machine operation.

  • Page 62: Replace The Drive Hub Oil

    Checklist D Procedures Replace the Drive Hub Oil Replace the Hydraulic Return Filter Genie specifications require that this procedure be performed every 1000 hours or annually, Genie specifications require that this procedure be whichever comes first. performed every 1000 hours or annually, whichever comes first.
  • Page 63 13 Move and hold the function enable toggle switch to either side and move and hold the primary boom toggle switch in the up direction. 14 Inspect the filter housing and related components to be sure that there are no leaks. Z-34/22 Bi-Energy Part No. 139234...

  • Page 64: Checklist E Procedures

    Disconnect and plug the hydraulic hose from the hydraulic tank shutoff valve. Bodily injury hazard. Spraying Genie specifications require that this procedure be hydraulic oil can penetrate and performed every 2000 hours or every two years, burn skin. Loosen hydraulic whichever comes first.

  • Page 65: Grease The Steer Axle Wheel Bearings, 2Wd Models

    Clean the suction strainer using a mild solvent. Genie specifications require that this procedure be 10 Rinse out the inside of the tank with a mild performed every 2000 hours or every two years, solvent.
  • Page 66 Refer to Specifications, Machine 13 Place the hub on a flat surface and gently pry Specifications. the bearing seal out of the hub. Remove the rear bearing. 14 Pack both bearings with clean, fresh grease. Part No. 139234 Z-34/22 Bi-Energy...

  • Page 67: Perform Engine Maintenance

    • Intake air line - replace Operator and Maintenance manuals. Required maintenance procedures and additional Kubota - Z482-E engine information are available in the following Operator and Maintenance manuals. Genie part number 52958 Kubota - Z482-E Genie part number 52958 Z-34/22 Bi-Energy...

  • Page 68: Repair Procedures

     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.
  • Page 69 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. 139234...

  • Page 70: Platform Controls

    Emergency Stop button to the the drive joystick controller. For further information on position at both the ground and platform or assistance, contact the Genie Product Support. controls. Open the platform control box lid and locate the boom function speed controller.
  • Page 71 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. 139234...

  • Page 72: Diodes

    Test Desired result red to black no continuity (infinite Ω) red to white no continuity black to white continuity (zero Ω) Part No. 139234 Z-34/22 Bi-Energy...

  • Page 73: Toggle Switches

    5 to 6 no continuity Left Center Right SPDT DPDT Note: Single pole double throw (SPDT). Double pole double throw (DPDT) Z-34/22 Bi-Energy Part No. 139234...

  • Page 74: Platform Components

    Move the platform level toggle switch up and under the platform for support. Lower the down through two platform leveling cycles to boom until the platform is resting on the remove any air that might be in the system. blocks. Part No. 139234 Z-34/22 Bi-Energy...

  • Page 75: Platform Rotator

    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. 139234...

  • Page 76: How To Bleed The Platform Rotator

    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. 139234 Z-34/22 Bi-Energy...

  • Page 77: Platform Overload System

    Note: The platform will need to be moved up and down and allowed to settle between adjustments. Confirm the setting: Turn the key switch to platform control. Lift the test weight off the platform floor using a suitable lifting device. Z-34/22 Bi-Energy Part No. 139234...
  • Page 78 10 Turn the key switch to ground control. 11 Test all machine functions from the ground controls. Result: All ground control functions should not operate. Note: If the platform overload system is not operating properly, repeat steps 1 through 4. Part No. 139234 Z-34/22 Bi-Energy...

  • Page 79: Jib Boom Components

    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. 139234...

  • Page 80: Jib Boom Bell Crank

    Crushing hazard. The jib boom jib boom lift cylinder rod-end pivot pin. Do not bellcrank may become remove the pin. unbalanced and fall if it is not properly supported when it is removed from the machine. Part No. 139234 Z-34/22 Bi-Energy...
  • Page 81 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. 139234...

  • Page 82: Primary Boom Components

    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.
  • Page 83 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. 139234...

  • Page 84: How To Disassemble The Primary Boom

    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. 139234 Z-34/22 Bi-Energy...

  • Page 85: Primary Boom Lift Cylinder

    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. 139234...
  • Page 86 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. 139234 Z-34/22 Bi-Energy...

  • Page 87: Primary Boom Extension Cylinder

    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. 139234...

  • Page 88: Platform Leveling Master Cylinder

    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. 139234 Z-34/22 Bi-Energy...
  • Page 89 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. 139234...

  • Page 90: Secondary Boom Components

    April 2016 Service Manual Secondary Boom Components 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. 139234 Z-34/22 Bi-Energy...

  • Page 91: Secondary Boom

    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. 139234...
  • Page 92 Use a soft metal drift to remove the pin. 31 Attach the strap from an overhead crane to the upper secondary boom. Part No. 139234 Z-34/22 Bi-Energy...
  • Page 93 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. 139234...

  • Page 94: Secondary Boom Lift Cylinders

    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. 139234 Z-34/22 Bi-Energy...
  • Page 95 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. 139234...

  • Page 96: Engines

    How to Remove the Engine Drive available in the Kubota Z482-E. Pulley Kubota Z482-E3B Operator's Manual Remove the engine pivot plate latch retainer. Genie part number 139420 Open the engine pivot plate latch and swing the engine out away from the machine to RPM Adjustment access the engine drive pulley.

  • Page 97: How To Install The Engine Drive Pulley

    2 shaft 3 set screw 4 engine drive pulley 5 engine drive pulley bolt 6 shaft bushing 7 woodruff key 1 pulley shaft 2 pulley bushing 3 engine flywheel 4 straightedge 5 generator pulley 6 generator Z-34/22 Bi-Energy Part No. 139234...

  • Page 98: Coolant Temperature And Oil Pressure Switches

    2 shaft switch opens. 3 set screw Component damage hazard.Do 4 engine drive pulley not crank the engine with the low 5 engine drive pulley bolt oil pressure light on. 6 shaft bushing 7 woodruff key Part No. 139234 Z-34/22 Bi-Energy...

  • Page 99: Generator

    Loosen the set screw on the pulley bushing, Generator Belts. 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. 139234...

  • Page 100: Generator Belts

    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. 139234 Z-34/22 Bi-Energy...

  • Page 101: Generator Voltage Regulator

    Note: The maximum range of motion of the 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. 139234...

  • Page 102: How To Replace The Voltage Regulator

    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. 139234 Z-34/22 Bi-Energy...
  • Page 103 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. 139234...

  • Page 104: Hydraulic Pumps

    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. 139234 Z-34/22 Bi-Energy...

  • Page 105: Function Pump

    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. 139234...

  • Page 106: April

    April 2016 Service Manual This page intentionally left blank. Part No. 139234 Z-34/22 Bi-Energy...

  • Page 107: Manifolds

    10-12 ft-lbs / 14-16 Nm L/min Flow regulator valve, 0.8 gpm / 3 Jib boom/platform rotate 10-12 ft-lbs / 14-16 Nm L/min circuit 3 position 4 way spool valve Turntable rotate left/right 10-12 ft-lbs / 14-16 Nm Z-34/22 Bi-Energy Part No. 139234...
  • Page 108 April 2016 Service Manual Manifolds Part No. 139234 Z-34/22 Bi-Energy...

  • Page 109: Valve Adjustments - Function Manifold

    Repeat steps 2 and 3 to confirm the relief valve pressure setting. Repeat steps 2 through 4 and recheck relief Remove the pressure gauge. valve pressure. Remove the pressure gauge. Z-34/22 Bi-Energy Part No. 139234...

  • Page 110: How To Adjust The Secondary Boom Down Relief Valve

    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. 139234 Z-34/22 Bi-Energy...

  • Page 111: Jib Boom / Platform Rotate Manifold Components

    Jib boom circuit 25-30 ft-lbs / 34-41 Nm Solenoid valve, 2 position 3 way Platform rotate circuit 25-30 ft-lbs / 34-41 Nm Flow regulator, 0.3 gpm / 1.2 L/min Platform rotate circuit 25-30 ft-lbs / 34-41 Nm Z-34/22 Bi-Energy Part No. 139234...

  • Page 112: Valve Coils

    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. 139234 Z-34/22 Bi-Energy...

  • Page 113: How To Test A Coil Diode

    Set a multimeter to read DC current. Resistor, 10Ω Note: The multimeter, when set to read DC current, Genie part number 27287 should be capable of reading up to 800 mA. Note: The battery should read 9V DC or more when measured across the terminals.

  • Page 114: Fuel And Hydraulic Tanks

    Component damage hazard. Do key switch and tag the machine not overtighten the fuel tank to inform personnel of the mounting fasteners. condition. Note: Clean the fuel tank and inspect for cracks and other damage before installing. Part No. 139234 Z-34/22 Bi-Energy...
  • Page 115 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. 139234...

  • Page 116: Turntable Rotation Components

    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. 139234 Z-34/22 Bi-Energy...

  • Page 117: Axle Components

    Remove the pin retaining fasteners from the upper and lower yoke pivot pins. Support the yoke/hub assembly with a lifting device. Place a rod through the yoke pivot pins and twist to remove the pins. Z-34/22 Bi-Energy Part No. 139234...

  • Page 118: How To Install The Hub And Bearings

    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. Part No. 139234 Z-34/22 Bi-Energy...

  • Page 119: Non-Steer Axle Components

    Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. Chock the steer wheels. Loosen the wheel lug nuts. Do not remove them. Z-34/22 Bi-Energy Part No. 139234...
  • Page 120 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. 139234 Z-34/22 Bi-Energy...

  • Page 121: Motor Controller

    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...

  • Page 122: Fault Codes

    • 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. 139234 Z-34/22 Bi-Energy...
  • Page 123 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.

  • Page 124: Fault Code Charts

    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. 139234 Z-34/22 Bi-Energy...
  • Page 125 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...
  • Page 126 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...
  • Page 127 Service Manual April 2016 This page intentionally left blank. Z-34/22 Bi-Energy Part No. 139234...

  • Page 128: Schematics

     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. 139234 Z-34/22 Bi-Energy...

  • Page 129: Electrical Symbol Legend

    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. 139234...

  • Page 130: Hydraulic Symbols Legend

    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. 139234 Z-34/22 Bi-Energy...
  • Page 131 Service Manual April 2016 This page intentionally left blank. Z-34/22 Bi-Energy Part No. 139234...
  • Page 132 April 2016 Service Manual Electrical Schematic - from serial number 4800 to 5426 (ANSI / CSA)

  • Page 133: Electrical Schematic - From Serial Number 4800 To 5426 (Ansi / Csa)

    Service Manual April 2016 Electrical Schematic - from serial number 4800 to 5426 (ANSI / CSA) Z-34/22 Bi-Energy Part No. 139234...
  • Page 134 April 2016 Service Manual Electrical Schematic - from serial number 4800 to 5426 (ANSI / CSA) Part No. 139234 Z-34/22 Bi-Energy...
  • Page 135 Service Manual April 2016 Electrical Schematic - from serial number 4800 to 5426 (ANSI / CSA)
  • Page 136 April 2016 Service Manual Electrical Schematic - from serial number 4800 to 5426 (CE)

  • Page 137: Electrical Schematic - From Serial Number 4800 To 5426 (Ce)

    Service Manual April 2016 Electrical Schematic - from serial number 4800 to 5426 (CE) Z-34/22 Bi-Energy Part No. 139234...
  • Page 138 April 2016 Service Manual Electrical Schematic - from serial number 4800 to 5426 (CE) Part No. 139234 Z-34/22 Bi-Energy...
  • Page 139 Service Manual April 2016 Electrical Schematic - from serial number 4800 to 5426 (CE)
  • Page 140 April 2016 Service Manual Electrical Schematic - from serial number 5427 to 9441 (ANSI / CSA)

  • Page 141: Electrical Schematic - From Serial Number 5427 To 9441 (Ansi / Csa)

    Service Manual April 2016 Electrical Schematic - from serial number 5427 to 9441 (ANSI / CSA) Z-34/22 Bi-Energy Part No. 139234...
  • Page 142 April 2016 Service Manual Electrical Schematic - from serial number 5427 to 9441 (ANSI / CSA) Part No. 139234 Z-34/22 Bi-Energy...
  • Page 143 Service Manual April 2016 Electrical Schematic - from serial number 5427 to 9441 (ANSI / CSA)
  • Page 144 April 2016 Service Manual Electrical Schematic - from serial number 9442 to 9685 (ANSI / CSA)

  • Page 145: Electrical Schematic - From Serial Number 9442 To 9685 (Ansi / Csa)

    Service Manual April 2016 Electrical Schematic - from serial number 9442 to 9685 (ANSI / CSA) Z-34/22 Bi-Energy Part No. 139234...
  • Page 146 April 2016 Service Manual Electrical Schematic - from serial number 9442 to 9685 (ANSI / CSA) Part No. 139234 Z-34/22 Bi-Energy...
  • Page 147 Service Manual April 2016 Electrical Schematic - from serial number 9442 to 9685 (ANSI / CSA)
  • Page 148 April 2016 Service Manual Electrical Schematic - from serial number 5247 to 9441 (CE)

  • Page 149: Electrical Schematic - From Serial Number 5427 To 9441(Ce)

    Service Manual April 2016 Electrical Schematic - from serial number 5427 to 9441(CE) Z-34/22 Bi-Energy Part No. 139234...
  • Page 150 April 2016 Service Manual Electrical Schematic - from serial number 5427 to 9441 (CE) Part No. 139234 Z-34/22 Bi-Energy...
  • Page 151 Service Manual April 2016 Electrical Schematic - from serial number 5427 to 9441(CE)
  • Page 152 April 2016 Service Manual Electrical Schematic - from serial number 9442 to 9685 (CE /AS)

  • Page 153: Electrical Schematic - From Serial Number 9442 To 9685 (Ce /As)

    Service Manual April 2016 Electrical Schematic - from serial number 9442 to 9685 (CE /AS) Z-34/22 Bi-Energy Part No. 139234...
  • Page 154 April 2016 Service Manual Electrical Schematic - from serial number 9442 to 9685 (CE /AS) Part No. 139234 Z-34/22 Bi-Energy...
  • Page 155 Service Manual April 2016 Electrical Schematic - from serial number 9442 to 9685 (CE /AS)
  • Page 156 April 2016 Service Manual Ground Control Box Switch Panel Wiring Diagram...

  • Page 157: Ground Control Box Switch Panel Wiring Diagram

    Service Manual April 2016 Ground Control Box Switch Panel Wiring Diagram Z-34/22 Bi-Energy Part No. 139234...

  • Page 158: Ground Control Box Terminal Strip Wiring Diagram

    April 2016 Service Manual Ground Control Box Terminal Strip Wiring Diagram Part No. 139234 Z-34/22 Bi-Energy...
  • Page 159 Service Manual April 2016 Ground Control Box Terminal Strip Wiring Diagram...
  • Page 160 April 2016 Service Manual Ground Control Box Terminal Strip Wiring Diagram - from serial number 9442 to 9685 (ANSI / CSA)

  • Page 161: Ground Control Box Terminal Strip Wiring Diagram - From Serial Number 9442 To 9685 (Ansi/Csa)

    Service Manual April 2016 Ground Control Box Terminal Strip Wiring Diagram - from serial number 9442 to 9685 (ANSI / CSA) Z-34/22 Bi-Energy Part No. 139234...

  • Page 162: Ground Control Box Terminal Strip Wiring Diagram - From Serial Number 9442 To 9685 (Ce /As)

    April 2016 Service Manual Ground Control Box Terminal Strip Wiring Diagram - from serial number 9442 to 9685 (CE /AS) Part No. 139234 Z-34/22 Bi-Energy...
  • Page 163 Service Manual April 2016 Ground Control Box Terminal Strip Wiring Diagram - from serial number 9442 to 9685 (CE /AS)
  • Page 164 April 2016 Service Manual Platform Control Box Wiring Diagram - to serial number 9441...

  • Page 165: Platform Control Box Wiring Diagram

    Service Manual April 2016 Platform Control Box Wiring Diagram - to serial number 9441 Z-34/22 Bi-Energy Part No. 139234...
  • Page 166 April 2016 Service Manual Platform Control Box Wiring Diagram - from serial number 9442 (CE) Part No. 139234 Z-34/22 Bi-Energy...
  • Page 167 Service Manual April 2016 Platform Control Box Wiring Diagram - from serial number 9442 (CE)
  • Page 168 April 2016 Service Manual Platform Control Box Wiring Diagram - from serial number 9442 (AS)
  • Page 169 Service Manual April 2016 Platform Control Box Wiring Diagram - from serial number 9442 (AS) Z-34/22 Bi-Energy Part No. 139234...

  • Page 170: Power Cable Wiring Diagram

    April 2016 Service Manual Power Cable Wiring Diagram Part No. 139234 Z-34/22 Bi-Energy...
  • Page 171 Service Manual April 2016 Power Cable Wiring Diagram...
  • Page 172 April 2016 Service Manual Drive Contactor Panel Wiring Diagram...

  • Page 173: Drive Contactor Panel Wiring Diagram

    Service Manual April 2016 Drive Contactor Panel Wiring Diagram Z-34/22 Bi-Energy Part No. 139234...

  • Page 174: Drive Contactor Panel Wiring Diagram - From 7223

    April 2016 Service Manual Drive Contactor Panel Wiring Diagram - from serial number 7223 Part No. 139234 Z-34/22 Bi-Energy...
  • Page 175 Service Manual April 2016 Drive Contactor Panel Wiring Diagram - from serial number 7223...

  • Page 176: Manifold And Limit Switch Wiring Diagram

    April 2016 Service Manual Manifold and Limit Switch Wiring Diagram...
  • Page 177 Service Manual April 2016 Manifold and Limit Switch Wiring Diagram...
  • Page 178 April 2016 Service Manual LVI / BCI Option Wiring Diagram, from serial number 4800 to 5426...

  • Page 179: Lvi / Bci Option Wiring Diagram, From Serial Number 4800 To 5426

    Service Manual April 2016 LVI / BCI Option Wiring Diagram, from serial number 4800 to 5426 Z-34/22 Bi-Energy Part No. 139234...

  • Page 180: Lvi / Bci Option Wiring Diagram, From Serial Number 5427

    April 2016 Service Manual LVI / BCI Option Wiring Diagram, from serial number 5427 Part No. 139234 Z-34/22 Bi-Energy...
  • Page 181 Service Manual April 2016 LVI / BCI Option Wiring Diagram, from serial number 5427...
  • Page 182 April 2016 Service Manual Engine Wiring Diagram...

  • Page 183: Engine Wiring Diagram

    Service Manual April 2016 Engine Wiring Diagram Z-34/22 Bi-Energy Part No. 139234...

  • Page 184: Hydraulic Schematic

    April 2016 Service Manual Hydraulic Schematic Part No. 139234 Z-34/22 Bi-Energy...
  • Page 185 Service Manual April 2016 Hydraulic Schematic Z-34/22 Bi-Energy Part No. 139234 Servic e M anual April 2016...

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