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
-30/20N
®
Z
-30/20N RJ
®
Z
-34/22
®
Z
-34/22N
®
Serial Number Range
from Z30NF-22000
from Z34F-14000
from Z34NF-17000
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. 1312293GT
Rev A
September 2021

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Summary of Contents for Terex Genie Z-34/22

  • Page 1 Service and Repair Manual Serial Number Range -30/20N ® from Z30NF-22000 This manual includes: Repair procedures -30/20N RJ ® Fault Codes Electrical and -34/22 ® from Z34F-14000 Hydraulic Schematics from Z34NF-17000 -34/22N ® For detailed maintenance procedures, refer to the appropriate Maintenance Manual for your machine.

  • Page 2: Find A Manual For This Model

    Copyright © 2015 by Terex Corporation 1312293GT Rev A, September 2021 Second Edition, First Printing Genie and "Z" are registered trademarks of Terex South Dakota, Inc. in the U.S.A. and many other countries. ® -30/20N • Z ®...

  • Page 3: Revision History

    September 2021 Service and Repair Manual Introduction Revision History Revision Date Section Procedure / Page / Description 9/2021 Initial Release Reference Examples: Electronic Version Section – Repair Procedure, 4-2 Click on any content or procedure in the Table of Contents to view Section –...

  • Page 4: Serial Number Legend

    Service and Repair Manual September 2021 Introduction Serial Number Legend Z30N F - 12345 Model: Z-30/20N Serial number: Z30NF-12345 Z-30/20N RJ Year of manufacture: Electrical schematic number: Machine unladen weight: Rated work load (including occupants): Maximum number of platform occupants: Maximum allowable side force: Z-34/22 Maximum allowable inclination of the chassis:...

  • Page 5: Safety Rules

    September 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. Many of the hazards identified in the operator's manual are also safety hazards when maintenance and repair procedures are...
  • Page 6 Service and Repair Manual September 2021 Safety Rules Personal Safety Workplace Safety Any person working on or around a machine Any person working on or around a machine must be aware of all known safety hazards. must be aware of all known safety hazards. Personal safety and the continued safe Personal safety and the continued safe operation of the machine should be your top...

  • Page 7: Table Of Contents

    September 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 September 2021 Table of Contents Section 3 Repair Procedures ..................12 Introduction ...................... 12 Platform Controls ................... 14 1-1 Controllers ....................14 Platform Components ..................16 2-1 Platform Leveling Slave Cylinder ..............16 2-2 Platform Rotator ..................17 2-3 Platform Overload System................18 Jib Boom Components ..................
  • Page 9 September 2021 Table of Contents Hydraulic Pump ....................43 6-1 Auxiliary and Function Pump ..............43 Manifolds ......................44 7-1 Function Manifold Components ..............44 7-2 Valve Adjustments - Function Manifold ............48 How to Adjust the System Relief Valve ............48 How to Adjust the Primary Boom Down Relief Valve ........
  • Page 10 September 2021 Table of Contents Section 4 Fault Codes ....................58 Introduction ...................... 58 Fault Code Charts ..................60 Section 5 Schematics ..................... 63 Introduction ...................... 63 Electrical Symbol Legend ................. 64 Hydraulic Symbols Legend ................65 Limit Switch Location Legend ................66 Electrical Schematics –...

  • Page 11: Specifications

    September 2021 Service and Repair Manual Specifications Secti on 2 Specificatio ns Machine Specifications Wheel lugs Front 8 @ 5/8 -18 Tires and wheels, Rear 9 @ 5/8 -18 Z-30/20N, Z-30/20N RJ and Z-34/22N Lug nut torque, dry 125 ft-lbs Tire size (solid rubber) 22 x 7 x 17.5 in 169.5 Nm...

  • Page 12: Machine Component Weights

    Service and Repair Manual September 2021 Specifications Machine Component Weights Machine Component Weights Z-30/20N and Z-30/20N RJ Z-34/22DC and Z-34/22N Drive motor 45 lbs Drive motor 64 lbs 20 kg 29 kg Torque hub 89 lbs Torque hub 113 lbs 40 kg 51 kg Primary boom assembly...

  • Page 13: Performance Specifications

    September 2021 Service and Repair Manual Specifications Performance Specifications Performance Specifications Z-30/20N and Z-30/20N RJ Z-34/22 and Z-34/22N Drive speed, maximum Drive speed, maximum Stowed position Stowed position 3.0 mph 4.0 mph 4.8 km/h 6.4 km/h 40 ft / 9.0 sec 40 ft / 6.8 sec 12.2 m / 9.0 sec 12.2 m / 6.8 sec...

  • Page 14: Hydraulic Oil Specifications

    Service and Repair Manual September 2021 Specifications Hydraulic Oil Specifications Do not top off with incompatible hydraulic fluids. Hydraulic fluids may be incompatible due to the Hydraulic Fluid Specifications differences in base additive Genie specifications require hydraulic oils which are chemistry.
  • Page 15 September 2021 Service and Repair Manual Specifications Chevron Rando HD Premium Oil Chevron 5606A Hydraulic Oil MV 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 cSt @ 104°F / 40°C 15.0...
  • Page 16 Service and Repair Manual September 2021 Specifications Petro-Canada Environ MV 46 UCON Hydrolube HP-5046 Fluid Fluid Properties Properties ISO Grade ISO Grade Viscosity index Viscosity index Kinematic Viscosity Kinematic Viscosity cSt @ 200°F / 100°C cSt @ 149°F / 65°C cSt @ 104°F / 40°C cSt @ 104°F / 40°C 44.4...

  • Page 17: Hydraulic Component Specifications

    September 2021 Service and Repair Manual Specifications Hydraulic Component Manifold Component Specifications Specifications Function Pump Plug torque Type Fixed displacement gear pump SAE No. 2 36 in-lbs / 4 Nm Displacement per revolution 0.183 cu in SAE No. 4 10 ft-lbs / 13 Nm 3 cc SAE No.

  • Page 18: Machine Torque Specifications

    Service and Repair Manual September 2021 Specifications Machine Torque Specifications Note: All torque values are shown lubricated unless otherwise noted. Platform rotator and jib boom rotator (Z-30/20N RJ) 1-8 center bolt, GR 5 480 ft-lbs (Jib boom rotator) 650 Nm 3/4 -10 bolt, GR 8 280 ft-lbs (Platform rotator)

  • Page 19: Hydraulic Hose And Fitting Torque Specifications

    September 2021 Service and Repair Manual Specifications 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...

  • Page 20: Torque Procedure

    Service and Repair Manual September 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 21 September 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 22: Repair Procedures

    Service and Repair Manual September 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 23 September 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 24: Platform Controls

    Service and Repair Manual September 2021 Platform Controls Boom Function Speed Controller Controllers Adjustments The drive joystick is connected to the drive motor Electrocution/burn hazard. controller, located under the drive chassis cover at Contact with electrically charged the non-steer end of the machine. Maintaining the circuits could result in death or boom function speed controller at the proper serious injury.
  • Page 25 September 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 26: Platform Components

    Service and Repair Manual September 2021 Platform Components Tag and disconnect the hydraulic hoses to the slave cylinder at the union and connect them Platform Leveling Slave Cylinder together with a connector. Cap the fittings on the cylinder hoses. The slave cylinder and the rotator pivot are the two primary supports for the platform.

  • Page 27: Platform Rotator

    September 2021 Service and Repair Manual Platform Components Support the jib boom, jib boom cylinder and leveling links with an overhead crane. Platform Rotator Use a soft metal drift to drive both pins out, then remove the platform rotator from the How to Remove the Platform machine.

  • Page 28: Platform Overload System

    Service and Repair Manual September 2021 Platform Components Move the function enable toggle switch to either side and hold the platform rotate toggle Platform Overload System switch to the left position until the platform is fully rotated to the left. Continue holding the How to Calibrate the Platform toggle switch until air stops coming out of the bleed screw.
  • Page 29 September 2021 Service and Repair Manual Platform Components Note: The platform will need to be moved up and Move the platform up and down by hand, so it down and allowed to settle between each bounces approximately 2.5 to 5 cm / 1 to adjustment.
  • Page 30 Service and Repair Manual September 2021 Platform Components Test all machine functions from the platform controls. Result: All platform control functions should not operate. 10 Turn the key switch to ground control. 11 Test all machine functions from the ground controls.

  • Page 31: Jib Boom Components

    September 2021 Service and Repair Manual Jib Boom Components Models with rotating jib boom: Tag, disconnect and plug the hydraulic hoses from Jib Boom the jib boom rotator. Cap the fittings on the rotator manifold. How to Remove the Jib Boom Bodily injury hazard.

  • Page 32: Jib Boom Bell Crank (Models Without Rotating Jib Boom)

    Service and Repair Manual September 2021 Jib Boom Components Remove the pin retaining fasteners from the jib boom lift cylinder rod-end pivot pin. Do not Jib Boom Bell Crank (models remove the pin. without rotating jib boom) 10 Models without rotating jib boom: Remove both of the jib boom leveling links from the How to Remove the Jib Boom bell crank.

  • Page 33: Jib Boom Bell Crank (Models With Rotating Jib Boom)

    September 2021 Service and Repair Manual Jib Boom Components Remove the pin retaining fasteners from the slave cylinder rod-end pivot pin. Do not Jib Boom Rotator (models with remove the pin. rotating jib boom) Place a block of wood under the platform leveling slave cylinder for support.
  • Page 34 Service and Repair Manual September 2021 Jib Boom Components Connect a clear hose to the top bleed valve. Fully rotate the jib boom to the left and Place the other end of the hose in a container continue holding the jib boom rotate toggle to collect any drainage.

  • Page 35: Jib Boom Lift Cylinder

    September 2021 Service and Repair Manual Jib Boom Components Remove the pin retaining fasteners from the jib boom lift cylinder rod-end pivot pin. Do not Jib Boom Lift Cylinder remove the pin. Use a soft metal drift to tap the rod-end pivot How to Remove the Jib Boom Lift pin half way out and lower one of the leveling Cylinder...

  • Page 36: Primary Boom Components

    Service and Repair Manual September 2021 Primary Boom Components How to Re pair the P rima ry Boo m Ca ble Track How to Repair the Primary Boom Cable Track Cable Track Component damage hazard. The primary boom cable track guides the cables The boom cable track can be and hoses running up the boom.

  • Page 37: Primary Boom

    September 2021 Service and Repair Manual Primary Boom Components How to Shim the Primary Boom How to Re mov e th e Prim ary Bo om How to Remove the Primary Boom Extend the boom until the wear pads are accessible.
  • Page 38 Service and Repair Manual September 2021 Primary Boom Components Tag, disconnect and cap the slave cylinder 12 Locate the cables from the primary boom hydraulic hoses at the union. Plug the hoses cable track to the platform control box. from the slave cylinder. Number each cable and its entry location at the platform control box.

  • Page 39: How To Disassemble The Primary Boom

    September 2021 Service and Repair Manual Primary Boom Components How to Disa ssem ble t he Pri mary Boom How to Disassemble the Primary 22 Attach a lifting strap from an overhead crane to the primary boom lift cylinder. Boom 23 Place 2 x 4 x 18 inch / 5 x 10 x 46 cm support Complete disassembly of the boom is only blocks under the cylinder, across the...

  • Page 40: Primary Boom Lift Cylinder

    Service and Repair Manual September 2021 Primary Boom Components Support and slide the extension tube out of the primary boom tube. Place the extension Primary Boom Lift Cylinder tube on blocks for support. The primary boom lift cylinder raises and lowers Note: During removal, the lifting device strap will the primary boom.
  • Page 41 September 2021 Service and Repair Manual Primary Boom Components Support the primary boom lift cylinder with a Remove the pin retaining fastener from the suitable lifting device. Place a block of wood ground control side upper secondary leveling across the upper secondary boom to support link pivot pin at the upper pivot (same side of the cylinder when the rod-end pin is removed.

  • Page 42: Primary Boom Extension Cylinder

    Service and Repair Manual September 2021 Primary Boom Components 15 Place a rod through the barrel-end pivot pin and twist to remove the pin. Primary Boom Extension Cylinder Crushing hazard. The primary boom lift cylinder could become unbalanced and fall if not The primary boom extension cylinder extends and properly supported by the lifting retracts the primary boom extension tube.The...
  • Page 43 September 2021 Service and Repair Manual Primary Boom Components Remove the external snap rings from the 11 Carefully pull out and properly support the extension cylinder rod-end pivot pins. Use a extension cylinder from the primary boom with soft metal drift to remove the pins. a lifting strap from an overhead crane.

  • Page 44: Platform Leveling Master Cylinder

    Service and Repair Manual September 2021 Primary Boom Components Tag, disconnect and plug the master cylinder hydraulic hoses. Cap the fittings on the Platform Leveling Master cylinder. Cylinder Bodily injury hazard. Spraying hydraulic oil can penetrate and The platform leveling master cylinder acts as a burn skin.

  • Page 45: Secondary Boom Components

    September 2021 Service and Repair Manual Secondary Boom Components Secondary Boom components 6 lower compression arm 1 upper pivot 7 turntable pivot 2 upper compression arm 8 counterweight (Z-30N / Z-30N RJ) 3 mid-pivot 9 upper secondary boom 4 compression link 5 lower secondary boom Part No.

  • Page 46: Secondary Boom

    Service and Repair Manual September 2021 Secondary Boom Components Remove the wire loom from the cables at the platform control box. Secondary Boom Locate the cables from the primary boom cable track to the platform control box. How to Disassemble the Number each cable and its entry location at Secondary Boom the platform control box.
  • Page 47 September 2021 Service and Repair Manual Secondary Boom Components 14 Remove the primary boom extend drive 22 Remove the pin retaining fasteners from the speed limit switch (LS1) mounted on the side upper pivot to upper secondary compression of the primary boom at the pivot end. Do not arm pivot pins.
  • Page 48 Service and Repair Manual September 2021 Secondary Boom Components 29 Use a soft metal drift to remove the upper 32 Tag, disconnect and plug the hydraulic hose secondary boom compression arm pivot pins from the hydraulic tank return filter housing. and remove the compression arm from the Cap the fitting on the filter housing.
  • Page 49 September 2021 Service and Repair Manual Secondary Boom Components 40 Attach a lifting strap from an overhead crane 45 Remove the mounting fasteners from the to the upper secondary boom. function manifold and slide the function manifold to the side. This will allow access to 41 Remove the pin retaining fastener from the the secondary boom lift cylinder barrel-end mid-pivot to upper secondary boom pivot pin.
  • Page 50 Service and Repair Manual September 2021 Secondary Boom Components 51 Use a slide hammer to remove the barrel-end 57 Attach a lifting strap from an overhead crane pivot pins (access the pins from the access to the ground control side lower secondary holes in the bulkheads, one on each side).

  • Page 51: Secondary Boom Lift Cylinders

    September 2021 Service and Repair Manual Secondary Boom Components Disconnect the battery packs from the machine. Secondary Boom Lift Cylinder Open the hydraulic tank side turntable cover. The secondary boom lift cylinder raises and lowers Tag and disconnect the power cables on the the secondary boom.
  • Page 52 Service and Repair Manual September 2021 Secondary Boom Components 18 Remove the hose clamp under the lower Tag, disconnect and plug the hydraulic hose secondary boom. from the hydraulic tank return filter housing. Cap the fitting on the filter housing. 19 Use a slide hammer to remove both barrel- end pivot pins (access the pins from the Bodily injury hazard.

  • Page 53: Hydraulic Pump

    September 2021 Service and Repair Manual Hydraulic Pump Tag, disconnect and plug the hydraulic hoses from the pump. Cap the fittings on the pump. Auxiliary and Function Pump Bodily injury hazard. Spraying hydraulic oil can penetrate and How to Remove the Auxiliary burn skin.

  • Page 54: Manifolds

    Service and Repair Manual September 2021 Manifolds 7-1 Function Manifold Components The function manifold is locate behind the ground controls turntable cover. Index Schematic Description Function Torque Item Solenoid valve, 3 position 4 way Platform level up/down 20-25 ft-lbs / 27-34 Counterbalance valve Platform level down 20-25 ft-lbs / 27-34...
  • Page 55 September 2021 Service and Repair Manual Manifolds Part No. 1312293GT ® -30/20N • Z ® -30/20N RJ • Z ® -34/22 • Z ® -34/22N...
  • Page 56 Service and Repair Manual September 2021 Manifolds Function Manifold Components, continued Index Schematic Description Function Torque Item Orifice, 0.045 inch / 1.14 mm Brake and steer circuit Solenoid Valve, N.O. poppet Brake circuit 20-25 ft-lbs / 27-34 Nm Differential sensing valve Differential sensing circuit 30-35 ft-lbs / 41-47 Nm Relief valve, System relief...
  • Page 57 September 2021 Service and Repair Manual Manifolds Part No. 1312293GT ® -30/20N • Z ® -30/20N RJ • Z ® -34/22 • Z ® -34/22N...

  • Page 58: Valve Adjustments - Function Manifold

    Service and Repair Manual September 2021 Manifolds 7-2 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 stowed position.

  • Page 59: How To Adjust The Secondary Boom Down Relief Valve

    September 2021 Service and Repair Manual Manifolds How to Adju st th e Seco nda ry Boo m Dow n Relief Valve How to Adjust the Secondary How to Adju st th e Prim ary Bo om Ext end R elief Valv e How to Adjust the Primary Boom Boom Down Relief Valve Extend Relief Valve...

  • Page 60: How To Adjust The Turntable Rotate Relief Valve

    Service and Repair Manual September 2021 Manifolds How to Adju st th e T urn table Rota te Relie f Valve How to Adjust the Turntable Rotate Relief Valve Note: Perform this procedure with the boom in the stowed position. Note: Refer to Function Manifold Component list to locate the turntable rotate relief valve.
  • Page 61 September 2021 Service and Repair Manual Manifolds Jib Boom and Platform / Jib Boom Rotate Manifold Components The jib boom/platform rotate manifold is mounted to the jib boom. Index Schematic Description Function Torque Item Solenoid valve, 3 position 4 way Jib boom up/down 20-25 ft-lbs / 27-34 Nm Solenoid valve, 3 position 4 way...

  • Page 62: Valve Coils

    Service and Repair Manual September 2021 Manifolds Valve Coil Resistance Valve Coils Specification Note: The following coil resistance specifications 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 electromotive force which operates the solenoid...

  • Page 63: How To Test A Coil Diode

    September 2021 Service and Repair Manual 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 64: Turntable Rotation Components

    Service and Repair Manual September 2021 Turntable Rotation Components Turntable Rotation Hydraulic Motor The turntable rotation hydraulic motor is the only serviceable component of the turntable rotation assembly. The worm gear must not be removed from the housing. In order to remove the housing, the turntable has to be removed.

  • Page 65: Steer Axle Components

    September 2021 Service and Repair Manual Steer Axle Components How to I nstall t he Hu b a nd Bea rings How to Install the Hub and 9-1 Hub and Bearings, 2WD Bearings Models Note: When replacing a wheel bearing, both the How to Re mov e th e Hub and Beari ngs inner and outer bearings, including the pressed-in How to Remove the Hub and...
  • Page 66 Service and Repair Manual September 2021 Steer Axle Components Loosen the castle nut one full turn and then torque to 35 ft-lbs / 47 Nm. 10 Install a new cotter pin. Bend the cotter pin to lock it in place. Note: Always use a new cotter pin when installing a castle nut.

  • Page 67: Non-Steer Axle Components

    September 2021 Service and Repair Manual Non-steer Axle Components 10-1 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 68: Fault Codes

    Service and Repair Manual September 2021 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 69 September 2021 Service and Repair Manual Fault Codes Fault Codes For example: the indicator light blinks 4 consecutive times, pauses for 1 second, and then blinks 1 time. That would indicate Fault Code Tip-over hazard. When adjusting the raised drive speed settings, the maximum raised drive speed must not exceed 0.6 mph / 1Km/h or 40 feet /...

  • Page 70: Fault Code Charts

    Service and Repair Manual September 2021 Fault Codes Fault C ode Cha rts Fault Code Chart Programmer Fault Code Condition Possible Causes Solution 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 71 September 2021 Service and Repair Manual Fault Codes Fault Code Chart Programmer Fault Code Condition 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...
  • Page 72 Service and Repair Manual September 2021 Fault Codes Fault Code Chart Programmer Fault Code 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.

  • Page 73: Schematics

    September 2021 Service and Repair Manual 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 74: Electrical Symbol Legend

    Service and Repair Manual September 2021 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 75: Hydraulic Symbols Legend

    September 2021 Service and Repair Manual 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 76: Limit Switch Location Legend

    Service and Repair Manual September 2021 Limit Switch Location Legend ® -30/20N • Z ® -30/20N RJ • Z ® -34/22 • Z ® -34/22N Part No. 1312293GT...

  • Page 77: Electrical Schematics - Options

    September 2021 Service and Repair Manual Power Cable Wiring Diagram...

  • Page 78: Power Cable Wiring Diagram

    Service and Repair Manual September 2021 Power Cable Wiring Diagram LEFT SIDE RIGHT SIDE AMMETER BATTERY PACK BK (10) BATTERY PACK WH (10) BATTERY CHARGER PRIMARY LIFT PUMP BK (4) AUX. LIFT PUMP BK (2) RD (2) BK (2) RD (2) BATTERY 3 DIODES CONTROLLER...

  • Page 79: Drive Contactor Panel Wiring Diagram

    September 2021 Service and Repair Manual Drive Contactor Panel Wiring Diagram 22 21 12 11 10 9 8 7 6 5 4 3 2 ES34DC AM Part No. 1312293GT ® -30/20N • Z ® -30/20N RJ • Z ® -34/22 • Z ®...
  • Page 80 Service and Repair Manual September 2021 Drive Contactor Panel Wiring Diagram...
  • Page 81 September 2021 Service and Repair Manual Manifold and Limit Switch Wiring Diagram...

  • Page 82: Manifold And Limit Switch Wiring Diagram

    Service and Repair Manual September 2021 Manifold and Limit Switch Wiring Diagram MANIFOLD HARNESS (MH) TO BASE CNTL. BOX (SHOWN WITH BOOM EXTENDED) PIN# WIRES SERVICE HORN PIN# WIRES PRESSURE SWITCH BRAKE RELEASE N.C. PIN# WIRES BRAKE RELEASE N.O. JIB MANIFOLD WITH JIB ROTATE OPTION JIB MANIFOLD W/O JIB ROTATE OPTION (TOP VIEW) (TOP VIEW)

  • Page 83: Lvi/Bci Option Wiring Diagram

    September 2021 Service and Repair Manual LVI/BCI Option Wiring Diagram P24BAT WH WH/RD ES34DC AM Part No. 1312293GT ® -30/20N • Z ® -30/20N RJ • Z ® -34/22 • Z ® -34/22N...
  • Page 84 Service and Repair Manual September 2021 LVI/BCI Option Wiring Diagram...
  • Page 85 September 2021 Service and Repair Manual Charger Interlock Option...

  • Page 86: Charger Interlock Option

    Service and Repair Manual September 2021 Charger Interlock Option ® -30/20N • Z ® -30/20N RJ • Z ® -34/22 • Z ® -34/22N Part No. 1312293GT...

  • Page 87: Cte Option, (Ce Models)

    September 2021 Service and Repair Manual CTE Option, (CE Models) Part No. 1312293GT ® -30/20N • Z ® -30/20N RJ • Z ® -34/22 • Z ® -34/22N...
  • Page 88 Service and Repair Manual September 2021 CTE Option, (CE Models)
  • Page 89 September 2021 Service and Repair Manual Contact Alarm Option...

  • Page 90: Contact Alarm Option

    Service and Repair Manual September 2021 Contact Alarm Option S 30 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 ES34DC AM ® -30/20N • Z ®...

  • Page 91: Electrical Schematics - Ansi / Csa Models

    September 2021 Service and Repair Manual Electrical Schematic [ANSI / CSA]...

  • Page 92: Electrical Schematic [Ansi / Csa]

    Service and Repair Manual September 2021 Electrical Schematic, (ANSI / CSA) C31REV WH/BK C30FWD WH C32JSL WH/RD C29JSH RD/WH P182BAT RD C27AUX RD FS1 RD-(FS) C9P-3 BK-(FS) C7P-1 P26BAT P26BAT C9P-1 BK WH-(FS) C9P-2 P24BAT WH P26BAT P26BAT RD R42PWR OR/RD C132PLI1 GR C1P-12 BL/WH...

  • Page 93: Electrical Schematic [Ansi / Csa]

    September 2021 Service and Repair Manual Electrical Schematic [ANSI / CSA] C31REV WH/BK C31REV WH/BK C30FWD WH C30FWD WH C32JSL WH/RD C32JSL WH/RD C29JSH RD/WH C29JSH RD/WH C27AUX RD LVI/BCI OPTION P24BAT WH P26BAT RD P24BAT WH R42PWR OR/RD P24PWR RD TURNTABLE PLATFORM SECONDARY...
  • Page 94 Service and Repair Manual September 2021 Electrical Schematic [ANSI / CSA]...
  • Page 95 September 2021 Service and Repair Manual Ground Control Box Terminal Strip Wiring Diagram [ANSI / CSA]...

  • Page 96: Ground Control Box Terminal Strip Wiring Diagram [Ansi / Csa]

    Service and Repair Manual September 2021 Ground Control Box Terminal Strip Wiring Diagram [ANSI / CSA] +48VDC ES34DC AM ® -30/20N • Z ® -30/20N RJ • Z ® -34/22 • Z ® -34/22N Part No. 1312293GT...

  • Page 97: Ground Control Box Switch Panel Wiring Diagram [Ansi / Csa]

    September 2021 Service and Repair Manual Ground Control Box Switch Panel Wiring Diagram [ANSI / CSA] TILT SENSOR ES34DC AM Part No. 1312293GT ® -30/20N • Z ® -30/20N RJ • Z ® -34/22 • Z ® -34/22N...
  • Page 98 Service and Repair Manual September 2021 Ground Control Box Switch Panel Wiring Diagram [ANSI / CSA]...
  • Page 99 September 2021 Service and Repair Manual Platform Control Box Wiring Diagram [ANSI / CSA]...

  • Page 100: Platform Control Box Wiring Diagram [Ansi / Csa]

    Service and Repair Manual September 2021 Platform Control Box Wiring Diagram, (ANSI / CSA) ES34DC AM JIB ROTATE OPTION...

  • Page 101: Electrical Schematics - Ce / As Models

    September 2021 Service and Repair Manual Electrical Schematic [CE / AS]...

  • Page 102: Electrical Schematic [Ce / As]

    Service and Repair Manual September 2021 Electrical Schematic [CE / AS] C31REV WH/BK C30FWD WH C32JSL WH/RD C29JSH RD/WH P182BAT RD C27AUX RD FS1 RD-(FS) C9P-3 C7P-1 P26BAT P26BAT C9P-1 BK BK-(FS) WH-(FS) C9P-2 P24BAT WH P26BAT P26BAT RD R42PWR OR/RD C132PLI1 GR C1P-12 BL/WH...

  • Page 103: Electrical Schematic [Ce / As]

    September 2021 Service and Repair Manual Electrical Schematic [CE / AS] C31REV WH/BK C31REV WH/BK C30FWD WH C30FWD WH C32JSL WH/RD C32JSL WH/RD C29JSH RD/WH C29JSH RD/WH C27AUX RD LVI/BCI OPTION P24BAT WH P26BAT RD P24BAT WH R42PWR OR/RD P24PWR RD TURNTABLE SECONDARY PRIMARY...
  • Page 104 Service and Repair Manual September 2021 Electrical Schematic [CE / AS]...
  • Page 105 September 2021 Service and Repair Manual Ground Control Box Terminal Strip Wiring Diagram [CE / AS]...

  • Page 106: Ground Control Box Terminal Strip Wiring Diagram [Ce / As]

    Service and Repair Manual September 2021 Ground Control Box Terminal Strip Wiring Diagram [CE / AS] +48VDC ES34DC AM ® -30/20N • Z ® -30/20N RJ • Z ® -34/22 • Z ® -34/22N Part No. 1312293GT...

  • Page 107: Ground Control Box Switch Panel Wiring Diagram [Ce / As]

    September 2021 Service and Repair Manual Ground Control Box Switch Panel Wiring Diagram [CE / AS] TILT SENSOR ES34DC AM Part No. 1312293GT ® -30/20N • Z ® -30/20N RJ • Z ® -34/22 • Z ® -34/22N...
  • Page 108 Service and Repair Manual September 2021 Ground Control Box Switch Panel Wiring Diagram [CE / AS]...
  • Page 109 September 2021 Service and Repair Manual Platform Control Box Wiring Diagram [CE / AS]...

  • Page 110: Platform Control Box Wiring Diagram [Ce / As]

    Service and Repair Manual September 2021 Platform Control Box Wiring Diagram [CE / AS] ES34DC AM JIB ROTATE OPTION ® -30/20N • Z ® -30/20N RJ • Z ® -34/22 • Z ® -34/22N Part No. 1312293GT...

  • Page 111: Hydraulic Schematics

    September 2021 Service and Repair Manual Hydraulic Schematic...

  • Page 112: Hydraulic Schematic

    Service and Repair Manual September 2021 Hydraulic Schematic NOTICE: CONTROLLED DOCUMENT. ANY CHANGES MUST BE APPROVED BY FACTORY MUTUAL APPROVALS. JOB ID: 3000448 JIB MANIFOLD Z30NRJ JIB ROTATE MANIFOLD 1100 PSI 7.6 CU. IN. /REV N.O. N.C. FSTL FSTR AUX. PRIMARY PUMP PUMP...

This manual is also suitable for:

Genie z-30/20nGenie z-30/20n rjGenie z-34/22n

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