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Terex Genie 20N RJ, Service And Repair Manual

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Terex Genie 20N RJ Service And Repair Manual Download Page 27

September 2021

 

Service and Repair Manual

 

 

Platform Controls

 

 

 

Part No. 1268498GT

 

Z®-30/20N • Z®-30/20N RJ •

 Z®-34/22 • Z®-34/22N 

15 

 

 

1-1 

Controllers 

The drive joystick is connected to the drive motor 

controller, located under the drive chassis cover at 

the non-steer end of the machine. Maintaining the 

boom function speed controller at the proper 

settings is essential to safe machine operation. The 

boom function speed controller should operate 

smoothly and provide proportional speed control 

through its entire range of motion. For further 

information or assistance, contact the Genie 

Product Support. 

 

1  boom function speed controller 
2  drive and brake printed circuit board 
3  drive joystick 

 

Boom Function Speed Controller 

Adjustments 

 

Electrocution/burn hazard. 

Contact with electrically charged 

circuits could result in death or 

serious injury. Remove all rings, 

watches and other jewelry. 

Note: Do not adjust the boom function speed 

controller unless the static battery supply voltage is 

above 24V DC. 
1  Turn the key switch to platform controls and 

pull out the red Emergency Stop button to the 

on position at both the ground and platform 

controls. 

2  Open the platform control box lid and locate 

the boom function speed controller. 

 

1  black/red wire 
2  diode 
3  white/red wire 
4  boom function speed controller 
5  ramp rate trimpot 
6  threshold trimpot 
7  max out trimpot 

 

Summary of Contents for Genie 20N RJ

Page 1: ...Codes Electrical and Hydraulic Schematics Z 34 22N Z3416F 11999 from Z34N14 10984 to Z34N16F 13999 Z 34 22DC from Z34N15D 102 to Z34N16D 279 from Z30NF 18900 to Z30NF 21999 from Z34F 12000 to Z34F 13999 from Z34NF 14000 to Z34NF 16999 For detailed maintenance procedures refer to the appropriate Maintenance Manual for your machine from Z30ND 200 from Z34ND 280 Part No 1268498GT Rev B September 2021...

Page 2: ...fined by ISO 16368 Machine Design Life Unrestricted with proper operation inspection and scheduled maintenance Technical Publications Genie has endeavored to deliver the highest degree of accuracy possible However continuous improvement of our products is a Genie policy Therefore product specifications are subject to change without notice Readers are encouraged to notify Genie of errors and send i...

Page 3: ...ew Release A1 4 2016 Schematics Update A2 9 2016 Introduction Serial Number Legend A3 3 2018 Specifications Performance Specifications B 9 2021 Cover Add ending serial break Reference Examples Electronic Version Click on any content or procedure in the Table of Contents to view the update Section Repair Procedure 4 2 Section Fault Codes All charts Section Schematics Legends and schematics ...

Page 4: ...268498GT Serial Number Legend To August 31 2016 1 Model 2 Model year 3 Facility code 4 Sequence number 5 Serial number stamped on chassis 6 Serial label located under cover From September 1 2016 1 Model 2 Facility code 3 Sequence number 4 Serial number stamped on chassis 5 Serial label located under cover ...

Page 5: ...or serious injury Many of the hazards identified in the operator s manual are also safety hazards when maintenance and repair procedures are performed Do Not Perform Maintenance Unless You are trained and qualified to perform maintenance on this machine You read understand and obey manufacturer s instructions and safety rules employer s safety rules and worksite regulations applicable governmental...

Page 6: ... of potential crushing hazards such as moving parts free swinging or unsecured components when lifting or placing loads Always wear approved steel toed shoes Workplace Safety Any person working on or around a machine must be aware of all known safety hazards Personal safety and the continued safe operation of the machine should be your top priority Be sure to keep sparks flames and lighted tobacco...

Page 7: ...er Legend iv Section 1 Safety Rules v General Safety Rules v Section 2 Specifications 1 Machine Specifications 1 Machine Component Weights 2 Performance Specifications 3 Hydraulic Specification 4 Hydraulic Component Specifications 7 Manifold Component Specifications 7 Machine Torque Specifications 8 Hydraulic Hose and Fitting Torque Specifications 9 Torque Procedure 10 SAE and Metric Fasteners Tor...

Page 8: ...Controls 15 1 1 Controllers 15 Platform Components 17 2 1 Platform Leveling Slave Cylinder 17 2 2 Platform Rotator 18 2 3 Platform Overload System 19 Jib Boom Components 22 3 1 Platform Overload System 22 3 2 Jib Boom Bell Crank models without rotating jib boom 23 3 3 Jib Boom Bell Crank models with rotating jib boom 24 3 4 Jib Boom Lift Cylinder 26 ...

Page 9: ...rm Leveling Master Cylinder 35 Secondary Boom Components 36 5 1 Secondary Boom 37 5 2 Secondary Boom Lift Cylinders 42 Hydraulic Pump 45 6 1 Auxiliary and Function Pump 45 Manifolds 46 7 1 Function Manifold Components 46 7 2 Valve Adjustments Function Manifold 50 How to Adjust the System Relief Valve 50 How to Adjust the Primary Boom Down Relief Valve 50 How to Adjust the Secondary Boom Down Relie...

Page 10: ...tation Components 57 8 1 Turntable Rotation Hydraulic Motor 57 Steer Axle Components 58 9 1 Hub and Bearings 58 How to Remove the Hub and Bearings 58 How to Install the Hub and Bearings 58 Non steer Axle Components 60 10 1 Motor Controller 60 Section 4 Fault Codes 61 Introduction 61 Fault Code Charts 63 ...

Page 11: ...Hydraulic Schematics 83 Hydraulic Schematic 84 Electrical Schematics ANSI CSA Models 85 Electrical Schematic ANSI CSA from serial numbers Z30N14 15222 Z34N14 10984 and Z3414 9686 86 Ground Control Box Terminal Strip Wiring Diagram ANSI CSA from serial numbers Z30N14 15222 Z34N14 10984 and Z3414 9686 87 Ground Control Box Terminal Strip Wiring Diagram ANSI CSA from serial numbers Z30N14 15222 Z34N1...

Page 12: ...14 15222 Z34N14 10984 and Z3414 9686 96 Ground Control Box Terminal Strip Wiring Diagram CE AS from serial numbers Z30N14 15222 Z34N14 10984 and Z3414 9686 100 Ground Control Box Switch Panel Wiring Diagram CE AS from serial numbers Z30N14 15222 Z34N14 10984 and Z3414 9686 101 Platform Control Box Wiring Diagram CE AS from serial numbers Z30N14 15222 Z34N14 10984 and Z3414 9686 104 ...

Page 13: ...2 Tire size 9 14 5 LT Tire ply rating 12 Tire weight new foam filled minimum 175 lbs 79 kg Overall tire diameter 28 in 71 cm Wheel diameter 14 5 in 37 cm Wheel width 7 in 18 cm Wheel lugs Front 8 5 8 18 Rear 9 5 8 18 Lug nut torque dry 125 ft lbs 169 5 Nm Lug nut torque lubricated 95 ft lbs 129 Nm Fuel capacities Hydraulic tank 4 gallons 15 1 liters Hydraulic system including tank 6 gallons 22 7 l...

Page 14: ...r 34 lbs 15 kg 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 Machine Component Weights Z 34 22DC and Z 34 22N Drive motor 64 lbs 29 kg Torque hub 113 lbs 51 kg Primary boom assembly including extension boom 647 lbs 293 kg Primary boom cylinder 59 lbs 27 kg Primary boom extend cylinder 75 lbs 34 kg Sec...

Page 15: ...ndary boom down 7 to 15 seconds Turntable rotate 355 62 to 68 seconds Platform rotate 180 5 to 11 seconds Platform level up 14 to 19 seconds Platform level down 13 to 18 seconds Performance Specifications Z 34 22 and Z 34 22N Drive speed maximum Stowed position 4 0 mph 6 4 km h 40 ft 6 8 sec 12 2 m 6 8 sec Boom raised or extended 0 6 mph1 km h40 ft 40 sec12 2 m 40 sec Braking distance maximum High...

Page 16: ...tant UCON Hydrolube HP 5046 Note Genie specifications require additional equipment and special installation instructions for the approved optional fluids Consult Genie Product Support before use Optional fluids may not have the same hydraulic lifespan and may result in component damage Note Extended machine operation can cause the hydraulic fluid temperature to increase beyond it s maximum allowab...

Page 17: ...nsistently below 0 F 18 C Note Do not operate the machine when the ambient temperature is below 20 F 29 C with Rando HD Premium MV Chevron 5606A Hydraulic Oil Fluid Properties ISO Grade 15 Viscosity index 300 Kinematic Viscosity cSt 200 F 100 C cSt 104 F 40 C cSt 40 F 40 C 5 5 15 0 510 Flash point 180 F 82 C Pour point 81 F 63 C Maximum continuous operating temperature 124 F 51 C Note Use of Chevr...

Page 18: ...80 F 82 C Shell Tellus S4 VX Fluid Properties ISO Grade 32 Viscosity index 300 Kinematic Viscosity cSt 200 F 100 C cSt 104 F 40 C 9 33 8 Brookfield Viscosity cSt 4 F 20 C cSt 13 F 25 C cSt 40 F 40 C 481 702 4 2624 Flash point 100 Pour point 76 F 60 C Maximum continuous operating temperature 103 F 75 C UCON Hydrolube HP 5046 Fluid Properties ISO Grade 46 Viscosity index 192 Kinematic Viscosity cSt ...

Page 19: ... Auxiliary pump Type Fixed displacement gear pump Displacement 0 3 gpm 1 14 L min Manifold Component Specifications Plug torque SAE No 2 36 in lbs 4 Nm SAE No 4 10 ft lbs 13 Nm SAE No 6 14 ft lbs 19 Nm SAE No 8 38 ft lbs 51 Nm SAE No 10 41 ft lbs 55 Nm SAE No 12 56 ft lbs 76 Nm Valve Coil Resistance Note The following coil resistance specifications are at an ambient temperature of 68 F 20 C As val...

Page 20: ...s 31 Nm 1 2 13 bolts GR 5 lubricated Jib boom rotator 57 ft lbs 77 Nm Platform rotator Z 30 20N Z 34 22 and Z 34 22N 3 4 10 bolt GR 8 lubricated 280 ft lbs 379 Nm 3 8 16 bolts GR 8 lubricated 23 ft lbs 31 Nm Turntable rotate bearing Rotate bearing mounting bolts lubricated 180 ft lbs 244 Nm Rotate bearing mounting bolts from serial numbers Z30N16F 17574 Z34N16F 12689 and Z3416F 10792 160 ft lbs 21...

Page 21: ...6 20 2 6 9 16 18 1 8 3 4 16 1 10 7 8 14 1 12 1 1 16 12 1 16 1 5 16 12 1 20 1 5 8 12 1 24 1 7 8 12 1 SAE O ring Boss Port tube fitting installed into Aluminum all types SAE Dash Size Torque 4 14 ft lbs 19 Nm 6 23 ft lbs 31 2 Nm 8 36 ft lbs 54 2 Nm 10 62 ft lbs 84 Nm 12 84 ft lbs 114 Nm 16 125 ft lbs 169 5 Nm 20 151 ft lbs 204 7 Nm 24 184 ft lbs 249 5 Nm Adjustable Fitting Non adjustable fitting 1 j...

Page 22: ...e seal is seated and retained properly 4 Position the tube and nut squarely on the face seal end of the fitting and tighten the nut finger tight 5 Tighten the nut or fitting to the appropriate torque Refer to the appropriate torque chart in this section 6 Operate all machine functions and inspect the hose fittings and related components to confirm there are no leaks JIC 37 fittings 1 Align the tub...

Page 23: ...ine the correct number of flats for the proper tightening position Note The marks indicate the correct tightening positions have been determined Use the second mark on the body hex fitting to properly tighten the joint after it has been loosened Illustration 2 1 body hex fitting 2 reference mark 3 second mark 4 Tighten the hex nut until the mark on the hex nut is aligned with the second mark on th...

Page 24: ...Service and Repair Manual September 2021 Specifications 12 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N Part No 1268498GT ...

Page 25: ...erator s manual on your machine 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 Machine Configuration Unless otherwise specified perform each repair procedure with the machine in the following configuration Machine ...

Page 26: ...bol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Indicates a imminently hazardous situation which if not avoided will result in death or serious injury Indicates a potentially hazardous situation which if not avoided could result in death or serious injury Indicates a potentially hazardous situation ...

Page 27: ...roduct Support 1 boom function speed controller 2 drive and brake printed circuit board 3 drive joystick Boom Function Speed Controller Adjustments Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Note Do not adjust the boom function speed controller unless the static battery supply voltage is ab...

Page 28: ...age or counterclockwise to decrease the amperage 7 Turn the boom function speed controller to the 9 position 8 Set the max out Press down the foot switch and move the primary boom toggle switch to the down position Adjust the amperage to 0 65A Turn the max out trimpot adjustment screw clockwise to increase the amperage or counterclockwise to decrease the amperage 9 Start a timer and simultaneously...

Page 29: ...d pivot pin is accessible 2 Raise the boom slightly and place blocks under the platform for support Lower the boom until the platform is resting on the blocks 3 Tag and disconnect the hydraulic hoses to the slave cylinder at the union and connect them together with a connector Cap the fittings on the cylinder hoses Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydr...

Page 30: ... any lifting pressure 6 Remove the pin retaining fasteners from the jib boom and leveling links to platform rotator pivot pins Do not remove the pins 7 Support the jib boom jib boom cylinder and leveling links with an overhead crane 8 Use a soft metal drift to drive both pins out then remove the platform rotator from the machine Crushing hazard The platform rotator could fall when removed from the...

Page 31: ...itch until air stops coming out of the bleed screw Close the bleed screw Crushing hazard Keep clear of the platform during rotation 7 Clean up any hydraulic oil that may have spilled 8 Rotate the platform fully in both directions and inspect the bleed screws for leaks 2 3 Platform Overload System How to Calibrate the Platform Overload System Calibration of the platform overload system is essential...

Page 32: ... both the platform and ground controls and the alarm sounds Proceed to step 7 Result The overload indicator lights are flashing at the platform and ground controls and the alarm is sounding Repeat this procedure beginning with step 5 Note The platform will need to be moved up and down and allowed to settle between each adjustment Note There may be a 2 second delay before the platform overload indi...

Page 33: ...ate 12 Using a suitable lifting device lift the test weight off the platform floor Result The platform overload indicator light should be off at both the ground and platform controls and the alarm should not sound Note There may be a 2 second delay before the overload indicator lights and alarm turn off 13 Test all machine functions from the ground controls Result All ground control functions shou...

Page 34: ...e wiring Component damage hazard Hoses and cables can be damaged if they are kinked or pinched 6 Models with rotating jib boom Tag disconnect and plug the hydraulic hoses from the jib boom rotator Cap the fittings on the rotator manifold Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually ...

Page 35: ...the overhead crane 3 2 Jib Boom Bell Crank models without rotating jib boom How to Remove the Jib Boom Bell Crank Note Perform this procedure with the boom in the stowed position 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 H...

Page 36: ... the jib boom rotator from the machine Crushing hazard The jib boom rotator could become unbalanced and fall when removed from the machine if not properly supported and secured to the lifting device Note When installing the jib boom rotator be sure to torque the fasteners to specification Refer to Specifications Machine Torque Specifications 5 Support and secure the jib boom bell crank to an appro...

Page 37: ...her side and move and hold the jib boom rotate toggle switch to the left for approximately 5 seconds then release it Repeat three times 5 Fully rotate the jib boom to the left and continue holding the jib boom rotate toggle switch until air stops coming out of the bleed valve Immediately release the platform rotate toggle switch and close the bleed valve Crushing hazard Keep hands and head clear o...

Page 38: ...linder Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 3 Remove the pin retaining fasteners from the jib boom lift cylinder rod end pivot pin Do not remove the pin 4 Use a soft metal drift to tap the rod end pivot pin half way out and lower one of th...

Page 39: ... when performing major repairs that involve removing the primary boom How to Re pair the P rima ry Boo m Ca ble Track How to Repair the Primary Boom Cable Track Component damage hazard The boom cable track can be damaged if it is twisted Note A 7 link repair section of cable track is available through the Genie Service Parts Department 1 link separation point 2 lower clip 1 Use a slotted screwdriv...

Page 40: ...ttempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended Note Perform this procedure with the boom in the stowed position 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 d...

Page 41: ...overhead 5 ton 5000 kg crane to the primary boom for support 12 Locate the cables from the primary boom cable track to the platform control box Number each cable and its entry location at the platform control box 13 Open the platform control box 14 Tag and disconnect each wire from the cables in the platform control box 15 Pull all the cables out of the platform control box 16 Remove the front cou...

Page 42: ...ry boom could become unbalanced and fall when removed from the machine if not properly attached to the overhead crane How to Disa ssem ble t he Pri mary Boom How to Disassemble the Primary Boom Note Complete disassembly of the boom is only necessary if the outer or inner boom tubes must be replaced The extension cylinder can be removed without completely disassembling the boom Refer to Repair Proc...

Page 43: ...moval the overhead crane strap will need to be adjusted for proper balancing 4 3 Primary Boom Lift Cylinder The primary boom lift cylinder raises and lowers the primary boom The primary boom lift cylinder is equipped with a counterbalance valve to prevent movement in the event of a hydraulic line failure How to Remove the Primary Boom Lift Cylinder Bodily injury hazard This procedure requires spec...

Page 44: ... a soft metal drift to remove the pin Crushing hazard The primary boom lift cylinder could become unbalanced and fall if not properly supported by the lifting device 8 Lower the rod end of the cylinder onto the blocks that were placed on the upper secondary boom 9 Remove the pin retaining fastener from the ground control side upper secondary leveling link pivot pin at the upper pivot same side of ...

Page 45: ...n cylinder extends and retracts the primary boom extension tube The primary boom extension cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure How to Remove the Primary Boom Extension Cylinder Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these ...

Page 46: ...primary boom extension cylinder hydraulic hoses Cap the fittings on the cylinder Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 10 Remove the retaining fastener from the extension cylinder barrel end pivot pin Use a soft metal drift to remove the pi...

Page 47: ...ust be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications 1 Raise the secondary boom until both the rod end and barrel end pivot pins of the master cylinder are accessible 2 Tag disconnect and plug the master cylinder hydraulic hoses Cap the fittings on the cylinder Bodily injury hazard Spraying hydraulic oil can penetrate and burn...

Page 48: ... Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N Part No 1268498GT Secondary Boom components 1 upper pivot 2 upper compression arm 3 mid pivot 4 compression link 5 lower secondary boom 6 lower compression arm 7 turntable pivot 8 counterweight Z 30N Z 30N RJ 9 upper secondary boom ...

Page 49: ...the battery packs from the machine 4 Remove the cable cover from the side of the jib boom 5 Remove the wire loom from the cables at the platform control box 6 Locate the cables from the primary boom cable track to the platform control box Number each cable and its entry location at the platform control box 7 Open the platform control box 8 Tag and disconnect each wire from the cables in the platfo...

Page 50: ...osition a lifting strap from the overhead crane approximately 2 feet 60 cm from the platform end of the primary boom Measure from the platform end of the primary boom tube 22 Remove the pin retaining fasteners from the upper pivot to upper secondary compression arm pivot pins Use a soft metal drift to remove the pins 23 Swing the compression arms down and out of the way Secure them from moving 24 ...

Page 51: ...ot oil Contact with hot oil may cause severe burns 32 Tag disconnect and plug the hydraulic hose from the hydraulic tank return filter housing Cap the fitting on the filter housing Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Bodily injury hazard ...

Page 52: ...embly of the machine the machine will become unstable and tip over Crushing hazard The counterweight could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane 45 Remove the mounting fasteners from the function manifold and slide the function manifold to the side This will allow access to the secondary boom lift cylinder barrel end pivot pin 46 R...

Page 53: ...oved from the machine if not properly supported by the overhead crane 56 Remove the secondary boom drive speed limit switch LS4 mounted to the turntable riser on the ground controls side Do not disconnect the wiring 57 Attach a lifting strap from an overhead crane to the ground control side lower secondary boom compression arm 58 Remove the pin retaining fastener from the lower secondary boom comp...

Page 54: ...orque Specifications 1 Rotate the turntable to either side until the boom is centered between the steer and non steer tires 2 Raise the primary boom to full height Do not extend it 3 Swing out the battery pack that is directly below the secondary boom lift cylinder 4 Disconnect the battery packs from the machine 5 Open the hydraulic tank side turntable cover 6 Tag and disconnect the power cables o...

Page 55: ...end pivot pin 15 Remove the mounting fasteners from the function manifold and slide the manifold to the side This will allow access to the hydraulic tank side barrel end pivot pin 16 Attach a lifting strap from an overhead crane to the lug on the rod end of the secondary boom lift cylinder 17 From the bottom side of the cylinder remove the retaining fasteners from the secondary boom lift cylinder ...

Page 56: ... the cylinder 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 24 Remove the cylinder through the top of the secondary boom Crushing hazard The secondary boom lift cylinder could become unbalanced and fall when removed from the machine if not properly...

Page 57: ... other jewelry 2 Close the hydraulic shutoff valve located at the hydraulic tank Component damage hazard The engine must not be started with the hydraulic tank shut off valves in the closed position or component damage will occur If the tank valves are closed remove the key from the key switch and tag the machine to inform personnel of the condition 3 Tag disconnect and plug the hydraulic hoses fr...

Page 58: ...e rotate left right 30 35 ft lbs 41 47 Nm 5 Relief valve 1600 psi 110 bar E Secondary boom down 20 25 ft lbs 27 34 Nm 6 Relief valve 1600 psi 110 bar F Primary boom down 20 25 ft lbs 27 34 Nm 7 Relief Valve 1800 psi 124 bar Z 30 N RJ r G Primary boom extend 20 25 ft lbs 27 34 Nm 8 Proportional solenoid valve H System flow regulating circuit 30 35 ft lbs 41 47 Nm 9 Check valve I Brake circuit 10 12...

Page 59: ...September 2021 Service and Repair Manual Manifolds Part No 1268498GT Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N 47 ...

Page 60: ... bar Z 34N and Z 34DC R System relief 20 25 ft lbs 27 34 Nm 19 Orifice 0 035 inch 0 89 mm S Tank return circuit 20 Diagnostic fitting T Testing 21 Solenoid valve 3 position 4 way U Secondary boom up down 20 25 ft lbs 27 34 Nm 22 Solenoid valve 3 position 4 way V Primary boom up down 20 25 ft lbs 27 34 Nm 23 Flow regulator valve 1 5 gpm 5 7 L min before serial number 10808 Flow regulator valve 1 8 ...

Page 61: ...September 2021 Service and Repair Manual Manifolds Part No 1268498GT Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N 49 ...

Page 62: ...lve higher than specified 6 Repeat steps 2 and 3 to confirm the relief valve pressure setting 7 Remove the pressure gauge How to Adju st th e Prim ary Bo om D own Reli ef Valve How to Adjust the Primary Boom Down Relief Valve Note Perform this procedure with the boom in the stowed position Note Refer to Function Manifold Component list to locate the primary boom down relief valve 1 Connect a 0 to ...

Page 63: ...ard Do not adjust the relief valve higher than specified 6 Repeat steps 2 and 3 to confirm the relief valve pressure setting 7 Remove the pressure gauge How to Adju st th e Prim ary Bo om Ext end R elief Valv e How to Adjust the Primary Boom Extend Relief Valve Note Perform this procedure with the boom in the stowed position 1 Connect a 0 to 3000 psi 0 to 200 bar pressure gauge to the test port on...

Page 64: ...top button to the on position 3 Move and hold the function enable toggle switch to either side and move and hold the turntable rotate toggle switch in the right direction until turntable stops against the rotation stop Observe the pressure reading on the pressure gauge Refer to Specifications Manifold Component Specifications 4 Turn the machine off Hold the turntable relief valve s with a wrench a...

Page 65: ...No Description Schematic Item Function Torque 1 Solenoid valve 3 position 4 way AA Jib boom up down 20 25 ft lbs 27 34 Nm 2 Solenoid valve 3 position 4 way AB Platform rotate left right 20 25 ft lbs 27 34 Nm 3 Solenoid valve 3 position 4 way AC Jib boom rotate left right 20 25 ft lbs 27 34 Nm 4 Flow regulator valve 0 3 gpm 1 14 L min AD Platform rotate circuit 20 25 ft lbs 27 34 Nm 5 Orifice plug ...

Page 66: ...e valve coil terminal then connect the negative lead from the ohmmeter to the internal ring of the valve coil 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 Valve Coil Resistance Specification Note The following coil resistance specifications are at an ambient temperature of 68 F 20 C As v...

Page 67: ...s watches and other jewelry 1 Test the coil for resistance See How to Test a Coil 2 Connect a 10Ω resistor to the negative terminal of a known good 9V DC battery Connect the other end of the resistor to a terminal on the coil Resistor 10Ω Genie part number 27287 Note The battery should read 9V DC or more when measured across the terminals 1 multimeter 2 9V DC battery 3 10Ω resistor 4 coil Note Dot...

Page 68: ... the connections Note and record the current reading Result Both current readings are greater than 0 mA and are different by a minimum of 20 The coil is good Result If one or both of the current readings are 0 mA or if the two current readings do not differ by a minimum of 20 the coil and or its internal diode are faulty and the coil should be replaced ...

Page 69: ... 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 1 Tag disconnect and plug the hydraulic hoses from the turntable rotation motor Cap the fittings on the motor Bodily injury hazard Spraying hydraulic ...

Page 70: ...r bearing Note When removing a bearing always use a new inner bearing seal How to I nstall t he Hu b a nd Bea rings How to Install the Hub and Bearings Note When replacing a wheel bearing both the inner and outer bearings including the pressed in races must be replaced 1 Be sure that both bearings are packed with clean fresh grease 2 Place the large inner bearing into the rear of the hub 3 Install...

Page 71: ...nd 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 11 Install the dust cap then the tire and wheel assembly 12 Lower the machine and remove the blocks 13 Torque the wheel lug nuts to specification Refer to Specifications Machine Torque Specifications ...

Page 72: ...tch to the off position and disconnect the battery packs from the machine 2 Tag and disconnect all power cables from the motor controller Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 3 Press the release tab on the motor controller harness connector and remove the motor controller harness conn...

Page 73: ...rols Wheels chocked 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 Before Troubleshooting Read understand and obey the safety rules and operating instructions in the appropriate operator s manual on your machine Be sure t...

Page 74: ...ld pendant motor controller programmer the M1 MAX SPEED needs to be set to 33 If needed adjust the M1 MAX SPEED higher or lower to achieve the maximum raised drive speed of 0 6 mph 1Km h or 40 feet 45 seconds 12 2 meters 45 seconds The controller status indicator light will flash a fault code to aid in troubleshooting This indicator light is mounted on the tilt level sensor mounting bracket locate...

Page 75: ...position If problem persists replace the motor controller 1 Normal operation 12 HW FAILSAFE 1 2 3 Machine will not drive The motor controller failed self test Replace the motor controller 13 M SHORTED Machine will not drive The motor controller has a internal short between M and B terminals Test the motor controller See Repair Section FIELD OPEN Machine will not drive Motor wiring is loose OR moto...

Page 76: ...ter on the drive joystick is defective Consult Genie Product Support 31 CONT DRVR OC Machine will not drive Main contactor PR1 coil defective OR brake release relay CR5 defective Replace main contactor PR1 or brake release relay CR5 OR replace the motor controller 32 MAIN CONT WELDED Machine will not drive Main contactor PR1 contacts stuck closed OR grn wire at pin 17 on motor controller shorted t...

Page 77: ...ller less than 32V DC Completely charge batteries OR check battery cable condition OR check for corrosion or loose connections at battery terminals and motor controller 42 OVERVOLTAGE Machine will not drive Battery supply voltage to motor controller more than 55V DC OR machine is being operated with the battery charger plugged in Be sure the battery charger is disconnected OR check for loose batte...

Page 78: ...Service and Repair Manual September 2021 66 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N Part No 1268498GT This page intentionally left blank ...

Page 79: ...nd 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 About This Section There are two groups of schematics in this section Electrical Schematics Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove...

Page 80: ...nnection no terminal T circuits connect at terminal Circuits crossing no connection Quick disconnect terminal Circuit breaker with amperage Key switch Toggle switch DPDT Toggle switch SPDT Pump or Motor Tilt sensor Horn button normally open Emergency stop button normally closed Resistor with ohm value Battery seperator Gauge sending unit Oil temperature switch normally open Coolant temperature swi...

Page 81: ...e valve 2 position 3 way Differential sensing valve Filter with bypass relief valve Relief valve with pressure setting Priority flow regulator valve Solenoid operated proportional valve Directional valve mechanically activated Flow divider combiner valve Pilot operated 3 position 3 way shuttle valve Solenoid operated 2 position 3 way directional valve Counterbalance valve with pressure and pilot r...

Page 82: ...Service and Repair Manual September 2021 Limit Switch Location Legend 70 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N Part No 1268498GT ...

Page 83: ...September 2021 Service and Repair Manual 71 Power Cable Wiring Diagram ...

Page 84: ...Service and Repair Manual September 2021 72 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N Part No 1268498GT Power Cable Wiring Diagram ...

Page 85: ...September 2021 Service and Repair Manual Part No 1268498GT Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N 73 Drive Contactor Panel Wiring Diagram ...

Page 86: ...Service and Repair Manual September 2021 74 Drive Contactor Panel Wiring Diagram ...

Page 87: ...September 2021 Service and Repair Manual 75 Manifold and Limit Switch Wiring Diagram ...

Page 88: ...Service and Repair Manual September 2021 76 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N Part No 1268498GT Manifold and Limit Switch Wiring Diagram ...

Page 89: ...September 2021 Service and Repair Manual Part No 1268498GT Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N 77 LVI BCI Option Wiring Diagram ...

Page 90: ...Service and Repair Manual September 2021 78 LVI BCI Option Wiring Diagram ...

Page 91: ...September 2021 Service and Repair Manual 79 Charger Interlock Option ...

Page 92: ...Service and Repair Manual September 2021 80 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N Part No 1268498GT Charger Interlock Option ...

Page 93: ...September 2021 Service and Repair Manual Part No 1268498GT Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N 81 CTE Option CE Models ...

Page 94: ...Service and Repair Manual September 2021 82 CTE Option CE Models ...

Page 95: ...September 2021 Service and Repair Manual 83 Hydraulic Schematic ...

Page 96: ...Service and Repair Manual September 2021 84 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N Part No 1268498GT Hydraulic Schematic ...

Page 97: ...September 2021 Service and Repair Manual 85 Electrical Schematic ANSI CSA from serial numbers Z30N14 15222 Z34N14 10984 and Z3414 9686 ...

Page 98: ...Service and Repair Manual September 2021 86 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N Part No 1268498GT Electrical Schematic ANSI CSA from serial numbers Z30N14 15222 Z34N14 10984 and Z3414 9686 ...

Page 99: ...September 2021 Service and Repair Manual Part No 1268498GT Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N 87 Electrical Schematic ANSI CSA from serial numbers Z30N14 15222 Z34N14 10984 and Z3414 9686 ...

Page 100: ...Service and Repair Manual September 2021 88 Electrical Schematic ANSI CSA from serial numbers Z30N14 15222 Z34N14 10984 and Z3414 9686 ...

Page 101: ...September 2021 Service and Repair Manual 89 Ground Control Box Terminal Strip Wiring Diagram ANSI CSA from serial numbers Z30N14 15222 Z34N14 10984 and Z3414 9686 ...

Page 102: ...and Repair Manual September 2021 90 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N Part No 1268498GT Ground Control Box Terminal Strip Wiring Diagram ANSI CSA from serial numbers Z30N14 15222 Z34N14 10984 and Z3414 9686 ...

Page 103: ...er 2021 Service and Repair Manual Part No 1268498GT Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N 91 Ground Control Box Switch Panel Wiring Diagram ANSI CSA from serial numbers Z30N14 15222 Z34N14 10984 and Z3414 9686 ...

Page 104: ...Service and Repair Manual September 2021 92 Ground Control Box Switch Panel Wiring Diagram ANSI CSA from serial numbers Z30N14 15222 Z34N14 10984 and Z3414 9686 ...

Page 105: ...September 2021 Service and Repair Manual 93 Platform Control Box Wiring Diagram ANSI CSA from serial numbers Z30N14 15222 Z34N14 10984 and Z3414 9686 ...

Page 106: ...rvice and Repair Manual September 2021 94 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N Part No 1268498GT Platform Control Box Wiring Diagram ANSI CSA from serial numbers Z30N14 15222 Z34N14 10984 and Z3414 9686 ...

Page 107: ...September 2021 Service and Repair Manual 95 Electrical Schematic CE AS from serial numbers Z30N14 15222 Z34N14 10984 and Z3414 9686 ...

Page 108: ...Service and Repair Manual September 2021 96 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N Part No 1268498GT Electrical Schematic CE AS from serial numbers Z30N14 15222 Z34N14 10984 and Z3414 9686 ...

Page 109: ...September 2021 Service and Repair Manual Part No 1268498GT Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N 97 Electrical Schematic CE AS from serial numbers Z30N14 15222 Z34N14 10984 and Z3414 9686 ...

Page 110: ...Service and Repair Manual September 2021 98 Electrical Schematic CE AS from serial numbers Z30N14 15222 Z34N14 10984 and Z3414 9686 ...

Page 111: ...September 2021 Service and Repair Manual 99 Ground Control Box Terminal Strip Wiring Diagram CE AS from serial numbers Z30N14 15222 Z34N14 10984 and Z3414 9686 ...

Page 112: ... and Repair Manual September 2021 100 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N Part No 1268498GT Ground Control Box Terminal Strip Wiring Diagram CE AS from serial numbers Z30N14 15222 Z34N14 10984 and Z3414 9686 ...

Page 113: ...ber 2021 Service and Repair Manual Part No 1268498GT Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N 101 Ground Control Box Switch Panel Wiring Diagram CE AS from serial numbers Z30N14 15222 Z34N14 10984 and Z3414 9686 ...

Page 114: ...Service and Repair Manual September 2021 102 Ground Control Box Switch Panel Wiring Diagram CE AS from serial numbers Z30N14 15222 Z34N14 10984 and Z3414 9686 ...

Page 115: ...September 2021 Service and Repair Manual 103 Platform Control Box Wiring Diagram CE AS from serial numbers Z30N14 15222 Z34N14 10984 and Z3414 9686 ...

Page 116: ...2N Part No 1268498GT Platform Control Box Wiring Diagram CE AS from serial numbers Z30N14 15222 Z34N14 10984 and Z3414 9686 Z 3 0 20N Z 30 2 0N RJ Z 34 22 Z 3 4 22N Part No 126 849 8GT Service a nd Re pair Ma nual Septem ber 202 1 Septem ber 202 1 Septem ber 202 1 Septem ber 202 1 ...

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