Terex Genie Z-34/22 Service And Repair Manual
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Terex Genie Z-34/22 Service And Repair Manual

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Service and Repair Manual
Z
-34/22
®
Bi-Energy Power
Serial Number Range
from Z3414-9686 to
Z3416F-11999
from Z34F-12000
This manual includes:
Repair procedures
Fault Codes
Electrical and
Hydraulic Schematics
For detailed maintenance
procedures, refer to the
appropriate Maintenance
Manual for your machine.
Part No. 1268515GT
Rev B
October 2021

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Summary of Contents for Terex Genie Z-34/22

  • Page 1 Service and Repair Manual Serial Number Range -34/22 ® from Z3414-9686 to This manual includes: Z3416F-11999 Repair procedures from Z34F-12000 Fault Codes Electrical and Hydraulic Schematics For detailed maintenance procedures, refer to the appropriate Maintenance Manual for your machine. Bi-Energy Power Part No.

  • Page 2: Find A Manual For This Model

    Copyright © 2015 by Terex Corporation 1268515GTRev B, October 2021 First Edition, Second Printing Genie and "Z" are registered trademarks of Terex South Dakota, Inc. in the U.S.A. and many other countries. ® -34/22 Bi-Energy Part No. 1268515GT...
  • Page 3 October 2021 Service and Repair Manual Introduction Revision History Revision Date Section Procedure / Page / Description 9/2015 Release 5/2016 Schematics Update, added Charger interlock option 9/2016 Introduction Serial Number Legend 10/2021 Schematics Electrical, Hydraulic Schematics Reference Examples: Electronic Version Section –...

  • Page 4: Serial Number Legend

    Service and Repair Manual October 2021 Introduction Serial Number Legend To August 31, 2016 1 Model 4 Sequence number 2 Model year 5 Serial number (stamped on chassis) 3 Facility code 6 Serial label (located under cover) From September 1, 2016 1 Model 4 Serial number (stamped on chassis) 2 Facility code...

  • Page 5: Safety Rules

    October 2021 Service and Repair Manual Safety Rules Secti on 1 Safety Rul es Danger Failure to obey the instructions and safety rules in this manual and the appropriate Operator's Manual on your machine will result in death or serious injury.
  • Page 6 Service and Repair Manual October 2021 Safety Rules Personal Safety Workplace Safety Any person working on or around a machine must Any person working on or around a machine must be aware of all known safety hazards. Personal be aware of all known safety hazards. Personal safety and the continued safe operation of the safety and the continued safe operation of the machine should be your top priority.

  • Page 7: Table Of Contents

    October 2021 Table of Contents Introduction Introduction ...................... ii Important Information ..................ii Find a Manual for this Model ................ii Revision History ....................iii Serial Number Legend ..................iv Section 1 Safety Rules ...................... v General Safety Rules ..................v Section 2 Specifications ....................
  • Page 8 October 2021 Table of Contents Section 3 Repair Procedures ..................12 Introduction ...................... 12 Platform Controls ................... 14 1-1 Controllers....................14 Boom Function Speed Controller Adjustments ..........14 1-2 Diodes......................16 1-3 Foot Switch ....................16 1-4 Toggle Switches ..................17 How to Test a Toggle Switch ...............
  • Page 9 October 2021 Table of Contents Primary Boom Components................25 4-1 Cable Track ....................25 How to Repair the Primary Boom Cable Track ..........25 4-2 Primary Boom .................... 25 How to Shim the Primary Boom ..............25 How to Remove the Primary Boom .............. 25 How to Disassemble the Primary Boom ............
  • Page 10 October 2021 Table of Contents Generator ......................42 7-1 Generator Pulley ..................42 How to Remove the Generator Pulley ............42 How to Install the Generator Pulley .............. 42 7-2 Generator Belts ..................43 7-3 Generator Voltage Regulator ..............44 How to Adjust the Generator Voltage Regulator ...........
  • Page 11 October 2021 Table of Contents Fuel and Hydraulic Tanks ................57 10-1 Fuel Tank ....................57 How to Remove the Fuel Tank..............57 10-2 Hydraulic Tank ..................57 How to Remove the Hydraulic Tank ............. 57 Turntable Rotation Components ..............59 11-1 Rotation Hydraulic Motor ................
  • Page 12 October 2021 Table of Contents Section 5 Schematics ..................... 70 Introduction ...................... 70 Electrical Symbol Legend ................. 71 Hydraulic Symbols Legend ................72 Electrical Schematic [from SN Z3414-9686 to Z34F-12065] (ANSI / CSA) ..74 Electrical Schematic [from SN Z3414-9686 to Z34F-12065] (ANSI / CSA) ..75 Electrical Schematic [from SN Z34F-12066] (ANSI / CSA) ........

  • Page 13: Specifications

    October 2021 Service and Repair Manual Specifications Secti on 2 Specificatio ns Machine Specifications Machine Component Weights Z-34/22DC and Z-34/22N Tires and wheels Industrial Tire size 9-14.5 LT Drive motor 64 lbs 29 kg Tire ply rating Tread 6 Sidewall 6 Torque hub 113 lbs 51 kg...

  • Page 14: Performance Specifications

    Service and Repair Manual October 2021 Specifications Performance Specifications Hydraulic Oil Specifications Drive speed, maximum Hydraulic Fluid Specifications Stowed position 3.7 mph Genie specifications require hydraulic oils which are designed to give maximum protection to hydraulic 5.9 km/h systems, have the ability to perform over a wide 40 ft / 7.5 sec temperature range, and the viscosity index should 12.2 m / 7.5 sec...
  • Page 15 October 2021 Service and Repair Manual Specifications Chevron Rando HD Premium Oil Do not top off with incompatible hydraulic fluids. Hydraulic fluids MV Fluid Properties may be incompatible due to the differences in base additive ISO Grade chemistry. When incompatible Viscosity index fluids are mixed, insoluble materials may form and deposit...
  • Page 16 Service and Repair Manual October 2021 Specifications Chevron 5606A Hydraulic Oil Petro-Canada Environ MV 46 Fluid Properties Fluid Properties ISO Grade ISO Grade Viscosity index Viscosity index Kinematic Viscosity Kinematic Viscosity cSt @ 200°F / 100°C cSt @ 200°F / 100°C cSt @ 104°F / 40°C 15.0 cSt @ 104°F / 40°C...

  • Page 17: Hydraulic Component Specifications

    October 2021 Service and Repair Manual Specifications UCON Hydrolube HP-5046 Fluid Hydraulic Component Properties Specifications ISO Grade Function Pump Viscosity index Type: fixed displacement gear pump Kinematic Viscosity Displacement per revolution 0.183 cu in cSt @ 149°F / 65°C 3 cc cSt @ 104°F / 40°C Auxiliary Pump cSt @ 0°F / -18°C...

  • Page 18: Manifold Component Specifications

    Service and Repair Manual October 2021 Specifications Manifold Component Machine Torque Specifications Specifications Platform Rotator 3/4-10 center bolt, GR 8, dry 380 ft-lbs Plug torque 515 Nm 3/4-10 center bolt, GR 8, lubricated SAE No. 2 36 in-lbs / 4 Nm 280 ft-lbs SAE No.

  • Page 19: Kubota Z482-E Engine Specifications

    October 2021 Service and Repair Manual Specifications Kubota Z482-E Engine Fuel requirement For fuel requirements, refer to the engine Operator Displacement 29.23 cu in Manual for your engine. 0.48 liters Injection system Number of cylinders Injection pump make Bosch MD Bore and Stroke 2.64 x 2.68 inches Injection timing...

  • Page 20: Generator Specifications

    Service and Repair Manual October 2021 Specifications Generator Generator output with engine @ 54V DC, 3000 rpm 100A Generator pulley to engine pulley offset, 1/16 inch maximum 1.6 mm Belt deflection, maximum 1/4 inch 6.5 mm Generator Torque Specifications Generator pulley retaining nut torque 80-90 ft-lbs 108-122 Nm Engine pulley retaining bolts...

  • Page 21: Hydraulic Hose And Fitting Torque Specifications

    October 2021 Service and Repair Manual Specifications Hydraulic Hose and Fitting SAE O-ring Boss Port Torque Specifications (tube fitting - installed into Aluminum) (all types) 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...

  • Page 22: Torque Procedure

    Service and Repair Manual October 2021 Specifications Torque Procedure JIC 37° fittings Align the tube flare (hex nut) against the nose Seal-Lok™ fittings of the fitting body (body hex fitting) and tighten the hex nut to the body hex fitting to Replace the O-ring.
  • Page 23 October 2021 Service and Repair Manual Specifications Working clockwise on the body hex fitting, make a second mark with a permanent ink marker to indicate the proper tightening position. Refer to Illustration 2. Note: Use the JIC 37° Fitting table in this section to determine the correct number of flats, for the proper tightening position.

  • Page 24: Repair Procedures

    Service and Repair Manual October 2021 Repair Procedures Machine Configuration: Secti on 3 Repair P roce dur es  Unless otherwise specified, perform each repair procedure with the machine in the following configuration: • Machine parked on a firm, level surface •...
  • Page 25 October 2021 Service and Repair Manual Repair Procedures About This Section Most of the procedures in this section should only be performed by trained service professional in a suitably equipped workshop. Select the appropriate repair procedure after troubleshooting the problem. Perform disassembly procedures to the point where repairs can be completed.

  • Page 26: Platform Controls

    Service and Repair Manual October 2021 Platform Controls Boom Functi on Sp eed C ont roller Adjust ment s Boom Function Speed Controller Adjustments Controllers Electrocution/burn hazard. Platform Controls Contact with electrically charged circuits could result in death or The drive joystick is connected to the drive motor serious injury.
  • Page 27 October 2021 Service and Repair Manual Platform Controls Locate the diode between the black/red wire 10 Set the ramp rate: Turn the ramp rate trimpot from the boom function speed controller and to obtain a 2 second delay from 0 to 0.65A. the white/red wire.

  • Page 28: Diodes

    Service and Repair Manual October 2021 Platform Controls Diodes Foot Switch How to Test a Diode How to Test the Foot Switch Connect the leads from an ohmmeter to each Turn the key switch to the off position. end of the diode. Remove the fasteners securing the foot switch to the platform and remove the bottom Re-connect the leads from the ohmmeter to...

  • Page 29: Toggle Switches

    October 2021 Service and Repair Manual Platform Controls Test Desired result Toggle Switches Left position terminal 1 to 2, 3, 4, 5 & 6 no continuity (infinite Ω) Toggle switches used for single function switching terminal 2 to 3 continuity (zero Ω) are single pole double throw (SPDT) switches.

  • Page 30: Platform Components

    Service and Repair Manual October 2021 Platform Components Remove the pin retainer fastener from the rod-end pivot pin. Platform Leveling Slave Cylinder Remove the external snap ring from the The slave cylinder and the rotator pivot are the two barrel-end pivot pin. primary supports for the platform.

  • Page 31: Platform Rotator

    October 2021 Service and Repair Manual Platform Components Support the platform rotator with a suitable lifting device. Do not apply any lifting Platform Rotator pressure. How to Re mov e th e Platfo rm R otat or How to Remove the Platform Remove the pin retaining fasteners from the jib boom and leveling links to platform rotator Rotator...

  • Page 32: How To Bleed The Platform Rotator

    Service and Repair Manual October 2021 Platform Components How to Blee d th e Platf orm Rota tor How to Bleed the Platform Move the function enable toggle switch to either side and hold the platform rotate toggle Rotator switch to the left position until the platform is fully rotated to the left.

  • Page 33: Platform Overload System

    October 2021 Service and Repair Manual Platform Components Note: There may be an approximate 2 second delay before the overload indicator light turns on Platform Overload System and the alarm sounds. Note: The platform will need to be moved up and How to Cali brat e th e Platf orm Ove rload Syste m (if equip ped ) How to Calibrate the Platform down and allowed to settle between adjustments.

  • Page 34: Jib Boom Components

    Service and Repair Manual October 2021 Jib Boom Components Tag and disconnect the electrical wiring from the jib boom manifold. Jib Boom Attach a lifting strap from an suitable lifting device to the jib boom. How to Remove the Jib Boom How to Re mov e th e Jib Bo om Remove the pin retaining fasteners from the Note: Perform this procedure with the boom in the...

  • Page 35: Jib Boom Bell Crank

    October 2021 Service and Repair Manual Jib Boom Components Jib Boom Bell Crank Jib Boom Lift Cylinder How to Re mov e th e Jib Bo om Bell C rank How to Remove the Jib Boom How to Re mov e th e Jib Bo om Lift Cylin der How to Remove the Jib Boom Lift Bell Crank Cylinder...
  • Page 36 Service and Repair Manual October 2021 Jib Boom Components 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.

  • Page 37: Primary Boom Components

    October 2021 Service and Repair Manual Primary Boom Components Primary Boom Cable Track The primary boom cable track guides the cables How to Shi m th e Prim ary Bo om How to Shim the Primary Boom and hoses running up the boom. It can be repaired Extend the boom until the wear pads are link by link without removing the cables and hoses accessible.
  • Page 38 Service and Repair Manual October 2021 Primary Boom Components Remove the platform rotator. Refer to Repair Tag, disconnect and plug the hydraulic hoses Procedure, How to Remove the Platform from the jib/rotate manifold. Rotator. Bodily injury hazard. Spraying Remove the jib boom. Refer to Repair hydraulic oil can penetrate and Procedure, How to Remove the Jib Boom.

  • Page 39: How To Disassemble The Primary Boom

    October 2021 Service and Repair Manual Primary Boom Components How to Disa ssem ble t he Pri mary Boom How to Disassemble the Primary 17 Tag, disconnect and plug the extension cylinder hydraulic hoses. Cap the fittings on Boom the cylinder. Note: Complete disassembly of the boom is only Bodily injury hazard.

  • Page 40: Primary Boom Lift Cylinder

    Service and Repair Manual October 2021 Primary Boom Components Support and slide the extension tube out of the outer primary boom tube. Place the Primary Boom Lift Cylinder extension boom tube on blocks for support. The primary boom lift cylinder raises and lowers Crushing hazard.
  • Page 41 October 2021 Service and Repair Manual Primary Boom Components Attach a lifting strap from an suitable lifting 13 Tag, disconnect and plug the primary boom device to the primary boom lift cylinder. lift cylinder hydraulic hoses. Cap the fittings on the cylinder. Remove the rear turntable cover.

  • Page 42: Primary Boom Extension Cylinder

    Service and Repair Manual October 2021 Primary Boom Components Remove the drive speed limit switch from the pivot end of the primary boom. Do not Primary Boom Extension disconnect the wiring. Cylinder Remove the pin retaining fasteners from the master cylinder rod end pivot pin. Use a soft The primary boom extension cylinder extends and metal drift to remove the pin.

  • Page 43: Platform Leveling Master Cylinder

    October 2021 Service and Repair Manual Primary Boom Components 10 Carefully pull out and properly support the extension cylinder from the primary boom Platform Leveling Master using a lifting strap from an suitable lifting Cylinder device. Crushing hazard. The extension The platform leveling master cylinder acts as a cylinder could fall when removed pump for the slave cylinder.
  • Page 44 Service and Repair Manual October 2021 Primary Boom Components Remove the rear turntable cover. Remove the pin retaining fasteners from the master cylinder rod-end pivot pin. Use a soft Raise the secondary boom until the master metal drift to remove the pin. cylinder barrel-end pivot pin is above the turntable counterweights.

  • Page 45: Secondary Boom Components

    October 2021 Service and Repair 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. 1268515GT ® -34/22 Bi-Energy...

  • Page 46: Secondary Boom

    Service and Repair Manual October 2021 Secondary Boom Components Locate the four cables from the primary boom cable track to the platform control box. Secondary Boom Number each cable and its entry location at the platform control box. How to Disa ssem ble t he Sec ond ary Bo om How to Disassemble the Open the platform control box.
  • Page 47 October 2021 Service and Repair Manual Secondary Boom Components 16 Carefully lift the secondary and primary boom 25 Carefully remove the entire primary boom assembly until the master and primary lift assembly from the machine (primary boom cylinder hydraulic hoses are accessible. assembly, jib boom assembly, platform, master cylinder, primary lift cylinder and upper 17 Remove the cable covers from the top of the...
  • Page 48 Service and Repair Manual October 2021 Secondary Boom Components 32 Remove the pin retaining fastener from the 39 Use a slide hammer to remove the barrel-end upper secondary boom to mid-pivot pivot pin. pins (access the pins from the access holes in Use a soft metal drift to remove the pin.

  • Page 49: Secondary Boom Lift Cylinders

    October 2021 Service and Repair Manual Secondary Boom Components 45 Remove the pin retainer from the lower compression arm to turntable pivot pin. Use a Secondary Boom Lift Cylinder slide hammer and remove the pin. Remove the arm from the machine. Repeat for the The secondary boom lift cylinder raises and lowers engine side lower compression arm.
  • Page 50 Service and Repair Manual October 2021 Secondary Boom Components 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).

  • Page 51: Engines

    October 2021 Service and Repair Manual Engines Engine Drive Pulley Timing Adjustment Complete information to perform this procedure is How to Re mov e th e Engin e Driv e Pulley 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.

  • Page 52: How To Install The Engine Drive Pulley

    Service and Repair Manual October 2021 Engines How to I nstall t he En gine D rive Pulley How to Install the Engine Drive Carefully tighten each bolt evenly until the engine drive pulley slides off the shaft. Pulley Component damage hazard. Note: The generator pulley must already be The engine drive pulley and/or installed before performing this procedure.

  • Page 53: Coolant Temperature And Oil Pressure Switches

    October 2021 Service and Repair Manual Engines Tighten the set screw on the pulley bushing Check the alignment between the engine hand tight. drive pulley and the generator pulley using a straightedge. Refer to Specifications, Slide the engine pulley onto the pulley Generator.

  • Page 54: Generator

    Service and Repair Manual October 2021 Generator How to I nstall t he G ene rato r Pulley How to Install the Generator Pulley Generator Pulley Note: The pulley on the generator must be How to Remove the Generator How to Re mov e th e Ge ner ator Pulley installed before installing the engine drive pulley.

  • Page 55: Generator Belts

    October 2021 Service and Repair Manual Generator Check the generator belts for proper tension. If the belt deflection is not within specification, Generator Belts perform steps 4 and 5 and re-check the belt tension. How to Adjust the Generator Belts Disconnect the battery packs.

  • Page 56: Generator Voltage Regulator

    Service and Repair Manual October 2021 Generator If the voltage reading is not 54V DC, insert a small flat blade screwdriver into the Generator Voltage Regulator potentiometer located inside of the generator. Use the access hole on the back of the How to Adju st th e Ge ner ato r Volta ge Re gulat or How to Adjust the Generator generator labeled volt adj.

  • Page 57: How To Replace The Voltage Regulator

    October 2021 Service and Repair Manual Generator How to Re place the Voltag e Reg ulato r How to Replace the Voltage 10 Locate the 3 white wires that lead from the voltage regulator to the negative rectifier Regulator assembly. Disconnect the battery packs from the machine.
  • Page 58 Service and Repair Manual October 2021 Generator 12 Locate the red wire that leads from the voltage regulator to the positive rectifier assembly. 13 Remove the screw that attaches the red wire to the positive rectifier assembly. 14 Remove the #4 nut that attaches the black wire to the voltage regulator.

  • Page 59: Hydraulic Pumps

    October 2021 Service and Repair Manual Hydraulic Pumps How to Remove the Auxiliary Pump Auxiliary Pump Note: When removing a hose assembly or fitting, How to Test the Auxiliary Pump How to Test the Au xiliary Pu mp the O-ring (if equipped) on the fitting and/or hose end must be replaced.

  • Page 60: Function Pump

    Service and Repair Manual October 2021 Hydraulic Pumps Function Pump How to Test the Fu nction P ump How to Test the Function Pump Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or hose end must be replaced.
  • Page 61 October 2021 Service and Repair Manual Hydraulic Pumps How to Remove the Function Pump Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or hose end must be replaced. All connections must be torqued to specification during installation. Refer to Specifications, Hydraulic Hose and Fitting Torque Specifications.

  • Page 62: Manifolds

    Service and Repair Manual October 2021 Manifolds 9-1 Function Manifold Components The function manifold is mounted to the turntable under the ground control box. Index Schematic Description Function Torque Item 3 position 4 way spool valve Platform level up/down 10-12 ft-lbs / 14-16 Nm Counterbalance valve Platform level down 35-40 ft-lbs / 47-54 Nm...
  • Page 63 October 2021 Service and Repair Manual Manifolds Part No. 1268515GT ® -34/22 Bi-Energy...

  • Page 64: Valve Adjustments - Function Manifold

    Service and Repair Manual October 2021 Manifolds 9-2 Valve Adjustments - Function How to Adju st th e Prim ary Bo om D own Reli ef Valve How to Adjust the Primary Boom Manifold Down Relief Valve Note: Perform this procedure with the boom in the How to Adju st th e Syste m Relie f Valve How to Adjust the System Relief stowed position.

  • Page 65: How To Adjust The Secondary Boom Down Relief Valve

    October 2021 Service and Repair Manual Manifolds How to Adju st th e Seco nda ry Boo m Dow n Relief Valve How to Adju st th e T urn table Rota te Relie f Valve How to Adjust the Secondary How to Adjust the Turntable Boom Down Relief Valve Rotate Relief Valve...

  • Page 66: Jib Boom / Platform Rotate Manifold Components

    Service and Repair Manual October 2021 Manifolds Jib Boom / Platform Rotate Manifold Components. The jib boom/platform rotate manifold is mounted to the jib boom. Index Schematic Description Function Torque Item Solenoid valve, 2 position 3 way Jib boom circuit 25-30 ft-lbs / 34-41 Nm Solenoid valve, 2 position 3 way Platform rotate circuit...

  • Page 67: Valve Coils

    October 2021 Service and Repair Manual Manifolds Valve Coil Resist anc e Specific ation Valve Coil Resistance Valve Coils Specifications Note: The following coil resistance specifications How to Test a Coil How to Test a Coil are at an ambient temperature of 68°F / 20°C. As valve coil resistance is sensitive to changes in air A properly functioning coil provides an temperature, the coil resistance will typically...

  • Page 68: How To Test A Coil Diode

    Service and Repair Manual October 2021 Manifolds How to Test a Coil Dio de How to Test a Coil Diode Properly functioning coil diodes protect the electrical circuit by suppressing voltage spikes. Voltage spikes naturally occur within a function circuit following the interruption of electrical current to a coil.

  • Page 69: Fuel And Hydraulic Tanks

    October 2021 Service and Repair Manual Fuel and Hydraulic Tanks 10-2 10-1 Hydraulic Tank Fuel Tank The primary functions of the hydraulic tank are to How to Remove the Fuel Tank How to Re mov e th e F uel Tank cool, clean and deaereate the hydraulic fluid during operation.
  • Page 70 Service and Repair Manual October 2021 Fuel and Hydraulic Tanks Place a suitable container under the hydraulic Remove the hydraulic tank mounting tank. Refer to Specifications, Machine fasteners. Specifications. Remove the hydraulic tank from the machine. Tag and disconnect and plug the hydraulic Crushing hazard.

  • Page 71: Turntable Rotation Components

    October 2021 Service and Repair Manual Turntable Rotation Components 11-1 Rotation Hydraulic Motor How to Remove the Turntable How to Re mov e th e T urnt able R otati on Moto r Rotation Motor Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or hose end must be replaced.

  • Page 72: Axle Components

    Service and Repair Manual October 2021 Axle Components Place a rod through the yoke pivot pins and 12-1 twist to remove the pins. Yoke and Hub Crushing hazard. The yoke/hub assembly may become How to Remove the Yoke and How to Re mov e th e Yoke and Hub unbalanced and fall when the yoke pivot pins are removed if it is not properly supported and...

  • Page 73: How To Install The Hub And Bearings

    October 2021 Service and Repair Manual Axle Components 12-2 How to I nstall t he Hu b a nd Bea rings How to Install the Hub and Steer Cylinder Bearings, 2WD Models Note: When replacing a wheel bearing, both the How to Remove a Steer Cylinder inner and outer bearings including the pressed-in races must be replaced.

  • Page 74: Non-Steer Axle Components

    Service and Repair Manual October 2021 Non-steer Axle Components 13-1 Drive Motor How to Remove a Drive Motor 1 Disconnect the battery packs. Tag and disconnect the power cables and relay wiring from the drive motor. Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury.

  • Page 75: Drive Hubs

    October 2021 Service and Repair Manual Non-steer Axle Components 13-2 Drive Hubs How to Remove a Drive Hub Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or hose end must be replaced. All connections must be torqued to specification during installation.

  • Page 76: Motor Controller

    Service and Repair Manual October 2021 Motor Controller 14-1 Set an ohmmeter to diode test mode. Motor Controller Connect the leads from an ohmmeter to test each motor controller terminal combination The drive motor controller is located under the listed below and check the forward / reverse non-steer end drive chassis cover.

  • Page 77: Fault Codes

    October 2021 Service and Repair Manual Fault Codes Before Troubleshooting: Secti on 4 Fault C odes  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 ...
  • Page 78 Service and Repair Manual October 2021 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 79: Fault Code Charts

    October 2021 Service and Repair Manual Fault Codes Fault C ode Cha rts Fault Code Chart Fault Code Programmer Condition Solution Possible Causes Diagnostic Display Fault code LED COMMUNICATION Machine will not drive. The key switch or Push in the ground is off or is on, ERROR Emergency Stop...
  • Page 80 Service and Repair Manual October 2021 Fault Codes Fault Code Chart Fault Code Programmer Condition Solution Possible Causes 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...
  • Page 81 October 2021 Service and Repair Manual Fault Codes Fault Code Chart Fault Code Programmer Condition Solution Possible Causes 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.

  • Page 82: Schematics

    Service and Repair Manual October 2021 Schematics About This Section Secti on 5 Schematic s There are two groups of schematics in this section. Electrical Schematics Electrocution/burn hazard. Contact with electrically charged Observe and Obey: circuits could result in death or serious injury.

  • Page 83: Electrical Symbol Legend

    October 2021 Service and Repair Manual Electrical Symbol Legend Battery Coil, solenoid or relay Horn or alarm Flashing beacon Gauge Diode Hour meter Fuse with amperage Foot switch T-circuits connect Limit switch Power relay Coil with suppression Fuel or RPM solenoid T-circuits connect at Circuits crossing no Quick disconnect...

  • Page 84: Hydraulic Symbols Legend

    Service and Repair Manual October 2021 Hydraulic Symbols Legend Orifice with size Check valve Shut off valve Brake Pump, bi-directional Motor, 2 speed bi- Pump, fixed displacement Motor, bi-directional variable displacement directional Pump, prime mover Shuttle valve. 2 position, Cylinder, double acting Differential sensing valve (engine or motor) 3 way...
  • Page 85 October 2021 Service and Repair Manual Electrical Schematic (ANSI / CSA) [from SN Z3414-9686 to Z34F-12065]...

  • Page 86: Electrical Schematic [From Sn Z3414-9686 To Z34F-12065] (Ansi / Csa)

    Service and Repair Manual October 2021 Electrical Schematic (ANSI / CSA) [from SN Z3414-9686 to Z34F-12065] ® -34/22 Bi-Energy Part No. 1268515GT...

  • Page 87: Electrical Schematic [From Sn Z3414-9686 To Z34F-12065] (Ansi / Csa)

    October 2021 Service and Repair Manual Electrical Schematic (ANSI / CSA) [from SN Z3414-9686 to Z34F-12065] Part No. 1268515GT ® -34/22 Bi-Energy...
  • Page 88 Service and Repair Manual October 2021 Electrical Schematic (ANSI / CSA) [from SN Z3414-9686 to Z34F-12065]...
  • Page 89 October 2021 Service and Repair Manual Electrical Schematic (ANSI / CSA) [from SN Z34F-12066]...

  • Page 90: Electrical Schematic [From Sn Z34F-12066] (Ansi / Csa)

    Service and Repair Manual October 2021 Electrical Schematic (ANSI / CSA) [from SN Z34F-12066] C31REV WH/BK C30FWD WH C32JSL WH/RD C29JSH RD/WH C27AUX RD P25BAT RD RD-(FS) C9-3 C7P-1 C9-1 BK BK-(FS) P26BAT BK WH-(FS) C9-2 P24BAT WH P24BAT WH P26BAT TB134 P26BAT RD...

  • Page 91: Electrical Schematic [From Sn Z34F-12066] (Ansi / Csa)

    October 2021 Service and Repair Manual Electrical Schematic (ANSI / CSA) [from SN Z34F-12066] C30FWD WH C31REV WH/BK C31REV WH/BK C30FWD WH C32JSL WH/RD C32JSL WH/RD C29JSH RD/WH C29JSH RD/WH C27 AUX RD LVI/BCI OPTION P24BAT WH P24BAT WH P26BAT RD R42PWR OR/RD TURNTABLE SECONDARY...
  • Page 92 Service and Repair Manual October 2021 Electrical Schematic (ANSI / CSA) [from SN Z34F-12066]...
  • Page 93 October 2021 Service and Repair Manual GBOX Switch Panel Wiring Diagram (ANSI / CSA) [from SN Z3414-9686]...

  • Page 94: Ground Control Box Switch Panel Wiring Diagram (Ansi / Csa)

    Service and Repair Manual October 2021 GBOX Switch Panel Wiring Diagram (ANSI / CSA) [from SN Z3414-9686] ® -34/22 Bi-Energy Part No. 1268515GT...

  • Page 95: Ground Control Box Terminal Strip Wiring Diagram (Ansi / Csa)

    October 2021 Service and Repair Manual GBOX Terminal Strip Wiring Diagram (ANSI / CSA) [from SN Z3414-9686] Part No. 1268515GT ® -34/22 Bi-Energy...
  • Page 96 Service and Repair Manual October 2021 GBOX Terminal Strip Wiring Diagram (ANSI / CSA) [from SN Z3414-9686]...
  • Page 97 October 2021 Service and Repair Manual PBOX Wiring Diagram (ANSI / CSA) [from SN Z3414-9686]...

  • Page 98: Platform Control Box Wiring Diagram - From Serial Number 9686 (Ansi / Csa)

    Service and Repair Manual October 2021 PBOX Wiring Diagram (ANSI / CSA) [from SN Z3414-9686] ® -34/22 Bi-Energy Part No. 1268515GT...
  • Page 99 October 2021 Service and Repair Manual Electrical Schematic (CE / AS) [from SN Z3414-9686 to Z34F-12065]...
  • Page 100 Service and Repair Manual October 2021 Electrical Schematic (CE / AS) [from SN Z3414-9686 to Z34F-12065] ® -34/22 Bi-Energy Part No. 1268515GT...

  • Page 101: Electrical Schematic [From Sn Z3414-9686 To Z34F-12065] (Ce / As)

    October 2021 Service and Repair Manual Electrical Schematic (CE / AS) [from SN Z3414-9686 to Z34F-12065] Part No. 1268515GT ® -34/22 Bi-Energy...

  • Page 102: Electrical Schematic [From Sn Z34F-12066] (Ce / As)

    Service and Repair Manual October 2021 Electrical Schematic (CE / AS) [from SN Z3414-9686 to Z34F-12065]...
  • Page 103 October 2021 Service and Repair Manual Electrical Schematic (CE / AS) [from SN Z34F-12066]...
  • Page 104 Service and Repair Manual October 2021 Electrical Schematic (CE / AS) [from SN Z34F-12066] C31REV WH/BK C30FWD WH C32JSL WH/RD C29JSH RD/WH C27AUX RD RD-(FS) C9-3 P25BAT RD BK-(FS) C7P-1 P26BAT BK C9P-1 BK WH-(FS) P24BAT WH C9-2 P24BAT WH P26BAT RD R42PWR OR/RD C132PLI2 GR...

  • Page 105: Electrical Schematic [From Sn Z34F-12066] (Ce / As)

    October 2021 Service and Repair Manual Electrical Schematic (CE / AS) [from SN Z34F-12066] C31REV WH/BK C30FWD WH C30FWD WH C31REV WH/BK C32JSL WH/RD C32JSL WH/RD C29JSH RD/WH C29JSH RD/WH C27 AUX RD LVI/BCI OPTION P24BAT WH P24BAT WH P26BAT RD R42PWR OR/RD RD/BK PLATFORM...
  • Page 106 Service and Repair Manual October 2021 Electrical Schematic (CE / AS) [from SN Z34F-12066]...
  • Page 107 October 2021 Service and Repair Manual GBOX Switch Panel Wiring Diagram (CE / AS) [from SN Z3414-9686]...

  • Page 108: Ground Control Box Switch Panel Wiring Diagram (Ce / As)

    Service and Repair Manual October 2021 GBOX Switch Panel Wiring Diagram (CE / AS) [from SN Z3414-9686] ® -34/22 Bi-Energy Part No. 1268515GT...

  • Page 109: Ground Control Box Terminal Strip Wiringdiagram (Ce / As)

    October 2021 Service and Repair Manual GBOX Terminal Strip Wiring Diagram (CE / AS) [from SN Z3414-9686] Part No. 1268515GT ® -34/22 Bi-Energy...
  • Page 110 Service and Repair Manual October 2021 GBOX Terminal Strip Wiring Diagram (CE / AS) [from SN Z3414-9686]...
  • Page 111 October 2021 Service and Repair Manual Platform Control Box Wiring Diagram (CE / AS) [from SN Z3414-9686]...

  • Page 112: Platform Control Box Wiring Diagram - From Serial Number 9686 (Ce / As)

    Service and Repair Manual October 2021 Platform Control Box Wiring Diagram (CE / AS) [from SN Z3414-9686] ® -34/22 Bi-Energy Part No. 1268515GT...

  • Page 113: Power Cable Wiring Diagram - From Serial Number Z3414-9686

    October 2021 Service and Repair Manual Power Cable Wiring Diagram [from SN Z3414-9686] Part No. 1268515GT ® -34/22 Bi-Energy...
  • Page 114 Service and Repair Manual October 2021 Power Cable Wiring Diagram [from SN Z3414-9686]...
  • Page 115 October 2021 Service and Repair Manual Drive Contactor Panel Wiring Diagram...

  • Page 116: Drive Contactor Panel Wiring Diagram

    Service and Repair Manual October 2021 Drive Contactor Panel Wiring Diagram ® -34/22 Bi-Energy Part No. 1268515GT...

  • Page 117: Manifold And Limit Switch Wiring Diagram

    October 2021 Service and Repair Manual Manifold and Limit Switch Wiring Diagram Part No. 1268515GT ® -34/22 Bi-Energy...
  • Page 118 Service and Repair Manual October 2021 Manifold and Limit Switch Wiring Diagram...
  • Page 119 October 2021 Service and Repair Manual LVI / BCI Option Wiring Diagram...

  • Page 120: Lvi / Bci Option Wiring Diagram

    Service and Repair Manual October 2021 LVI / BCI Option Wiring Diagram ® -34/22 Bi-Energy Part No. 1268515GT...

  • Page 121: Charger Interlock Option

    October 2021 Service and Repair Manual Charger Interlock Option Part No. 1268515GT ® -34/22 Bi-Energy...
  • Page 122 Service and Repair Manual October 2021 Charger Interlock Option...
  • Page 123 October 2021 Service and Repair Manual Engine Wiring Diagram...

  • Page 124: Engine Wiring Diagram

    Service and Repair Manual October 2021 Engine Wiring Diagram ® -34/22 Bi-Energy Part No. 1268515GT...

  • Page 125: Contact Alarm, Option [From Sn Z34F-12066]

    October 2021 Service and Repair Manual Contact Alarm, Option [from SN Z34F-12066] SW30 J110 C111A-2 C111B-2 OR/BK L18B L18A C111A-1 C111B-1 R24BAT BK/RD BK/RD R24BAT BK/RD BK/WH BK/WH CR81 C9P-1 C9A-2 C9A-1 P24BAT WH P24FS WH C9P-2 HORN ES34BE AK Part No.
  • Page 126 Service and Repair Manual October 2021 Contact Alarm, Option [from SN Z34F-12066]...
  • Page 127 October 2021 Service and Repair Manual Fuel Level Sensor, Option [from SN Z34F-12066]...

  • Page 128: Fuel Level Sensor, Option [From Sn Z34F-12066]

    Service and Repair Manual October 2021 Fuel Level Sensor, Option [from SN Z34F-12066] D81CAN- C53-4 4 CAN- D82CAN+ C53-3 3 CAN+ C134PWR C53-2 1 POWER C53-1 6 GROUND 2 SENSOR INPUT ES34BE AL ® -34/22 Bi-Energy Part No. 1268515GT...

  • Page 129: Hydraulic Schematics

    October 2021 Service and Repair Manual Hydraulic Schematic...

  • Page 130: Hydraulic Schematic

    Service and Repair Manual October 2021 Hydraulic Schematic JIB MANIFOLD Z30NRJ JIB ROTATE MANIFOLD 1100 PSI 7.6 CU. IN. /REV N.O. N.C. FSTL FSTR PRIMARY AUX. PUMP PUMP 1600 PSI 1600 PSI 1100 PSI 3000 PSI RESERVOIR FUNCTION MANIFOLD Z®-3 4/22 Bi-Ener gy Part No.

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