Terex Genie Z-34/22DC Service Manual Download

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April 2016

Table of Contents

Z-30/20N • Z-30/20N RJ • Z-34/22

• Z-34/22N

Part No. 139378

Section 4

Repair Procedures ............................................................................................. 45

Introduction .......................................................................................................... 45

Platform Controls ............................................................................................... 47

1-1 Controllers ...................................................................................................... 47

Platform Components ....................................................................................... 49

2-1 Platform Leveling Slave Cylinder ................................................................... 49

2-2 Platform Rotator ............................................................................................. 50

2-3 Platform Overload System ............................................................................. 51

Jib Boom Components ...................................................................................... 54

3-1 Platform Overload System ............................................................................. 54

3-2 Jib Boom Bell Crank (models without rotating jib boom) ............................... 55

3-3 Jib Boom Bell Crank (models with rotating jib boom) .................................... 56

3-4 Jib Boom Lift Cylinder .................................................................................... 58

Primary Boom Components ............................................................................. 59

4-1 Cable Track.................................................................................................... 59

How to Repair the Primary Boom Cable Track ............................................... 59

4-2 Primary Boom ................................................................................................ 60

How to Remove the Primary Boom ................................................................ 60

How to Disassemble the Primary Boom ......................................................... 62

4-3 Primary Boom Lift Cylinder ............................................................................ 63

4-4 Primary Boom Extension Cylinder ................................................................. 65

4-5 Platform Leveling Master Cylinder ................................................................. 67

Secondary Boom Components ........................................................................ 68

5-1 Secondary Boom ........................................................................................... 69

5-2 Secondary Boom Lift Cylinders ..................................................................... 74

Hydraulic Pump .................................................................................................. 77

6-1 Auxiliary and Function Pump ......................................................................... 77

Summary of Contents for Genie Z-34/22DC

Page 1: ...ervice Manual Serial Number Range Z 30 20N from Z30N08 11500 to Z30N14 15221 Z 30 20N RJ from Z34N07 6291 to Z34N07 10983 Z 34 22N from Z3407 5427 to Z3414 9685 Z 34 22DC Part No 139378 Rev C1 April 2016 ...

Page 2: ...cation Group B Type 3 as defined 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...

Page 3: ...story Maint Added B 15 Test the Emergency Power C 9 2015 Added ending serial breaks C1 3 2016 Schematics Specifications Added Schematics Added Commponent Weights Reference Examples Section Maintenance B 3 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 schemat...

Page 4: ...ion History Revision Date Section Procedure Page Description Reference Examples Section Maintenance B 3 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 5: ...Service Manual Introduction Part No 139378 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N v Serial Number Legend 1 Model 2 Model year 3 Sequence number 4 Serial number stamped on chassis 5 Serial label located under cover ...

Page 6: ...s 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 regulati...

Page 7: ...ntial 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 away fr...

Page 8: ...raulic 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 Torque Charts 12 Section 3 Scheduled Maintenance Procedures 13 Introduction 13 Pre Delivery Preparation Report 16 Maintenance Inspection Report 18 Checklist A Procedures 19 A 1 Inspect the Manuals and D...

Page 9: ... 29 B 11 Test the Alarm Package if equipped 30 B 12 Test the Turntable Rotation Stop 31 B 13 Check the Electrical Contactors 31 B 14 Perform Hydraulic Oil Analysis 32 B 15 Test the Emergency Power System 32 Checklist C Procedures 34 C 1 Grease the Platform Overload Mechanism if equipped 34 C 2 Test the Platform Overload System if equipped 34 Checklist D Procedures 36 D 1 Check the Boom Wear Pads 3...

Page 10: ...ank models without rotating jib boom 55 3 3 Jib Boom Bell Crank models with rotating jib boom 56 3 4 Jib Boom Lift Cylinder 58 Primary Boom Components 59 4 1 Cable Track 59 How to Repair the Primary Boom Cable Track 59 4 2 Primary Boom 60 How to Remove the Primary Boom 60 How to Disassemble the Primary Boom 62 4 3 Primary Boom Lift Cylinder 63 4 4 Primary Boom Extension Cylinder 65 4 5 Platform Le...

Page 11: ...he Turntable Rotate Relief Valve 84 7 3 Jib Boom and Platform Jib Boom Rotate Manifold Components 85 7 4 Valve Coils 87 How to Test a Coil Diode 88 Turntable Rotation Components 90 8 1 Turntable Rotation Hydraulic Motor 90 Steer Axle Components 91 9 1 Hub and Bearings 91 How to Remove the Hub and Bearings 91 How to Install the Hub and Bearings 91 Non steer Axle Components 93 10 1 Motor Controller ...

Page 12: ... 8857 and Z3410 7774 121 Ground Control Box Terminal Strip Wiring Diagram ANSI CSA AS before serial numbers Z3010 12119 Z34N10 8857 and Z3410 7774 124 Ground Control Box Switch Panel Wiring Diagram ANSI CSA AS before serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 125 Platform Control Box Wiring Diagram ANSI CSA AS before serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 128 Electrical...

Page 13: ... Z3414 9685 155 Electrical Schematics AS CE Models 157 Electrical Schematic AS CE from serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 to Z30N13 14695 Z34N13 10622 and Z3413 9441 158 Electrical Schematic AS CE from Z30N13 14696 Z34N13 10623 and Z3413 9442 to Z30N14 15221 Z34N14 10983 and Z3414 9685 162 Ground Control Box Terminal Strip Wiring Diagram AS CE from serial numbers Z30N10 12119 Z...

Page 14: ...e 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 liters Driv...

Page 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 30 20N and Z 30 20N RJ Drive motor 45 lbs 20 kg Torque hub 89 lbs 40 kg Primary boom assembly including extension boom 541 lbs 226 kg Primary boom cylinder 59 lbs 27 kg Primary boom extend cylinder 66 lbs 30 kg Secondary boo...

Page 16: ...m 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 5 mph 7 2 km h 40 ft 6 0 sec 12 2 m 6 0 sec Boom raised or extended 0 6 mph1 km h40 ft 42 sec12 2 m 42 sec Braking distance maximum High range on...

Page 17: ... 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 allowable range ...

Page 18: ...y 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 Chevron 5606A ...

Page 19: ... 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 149 F 65 ...

Page 20: ...y 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 valve coil r...

Page 21: ... bolts GR 8 lubricated Platform rotator 23 ft lbs 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 Drive hubs brakes and motors Drive hub mounting bolts lubric...

Page 22: ...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 jam nut SA...

Page 23: ... 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 tube flare h...

Page 24: ...orrect 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 the body he...

Page 25: ...Service Manual April 2016 Specifications 12 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N Part No 139378 ...

Page 26: ...ed may cause death serious injury or substantial damage Immediately tag and remove from service a damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Use only Genie approved replacement parts Machines that have been out of service for a period longer than 3 months must complete the quarterly inspection Machine Configuration Unless otherwise speci...

Page 27: ... Indicates a potentially hazardous situation which if not avoided may cause minor or moderate injury Indicates a potentially hazardous situation which if not avoided may result in property damage Indicates that a specific result is expected after performing a series of steps Indicates that an incorrect result has occurred after performing a series of steps Maintenance Symbols Legend Note The follo...

Page 28: ...s Use the following chart to determine which group s of procedures are required to perform a scheduled inspection Inspection Checklist Daily or every 8 hours A Quarterly or every 250 hours A B Semi annually or every 500 hours A B C Annually or every 1000 hours A B C D Two year or every 2000 hours A B C D E Maintenance Inspection Report The maintenance inspection report contains checklists for each...

Page 29: ...ualified service technicians according to the manufacturer s specifications and the requirements listed in the responsibilities manual Instructions Use the operator s manual on your machine The Pre delivery Preparation consists of completing the Pre operation Inspection the Maintenance items and the Function Tests Use this form to record the results Place a check in the appropriate box after each ...

Page 30: ...April 2016 Service Manual Part No 139378 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N 17 This page intentionally left blank ...

Page 31: ... After repair place a check in the R box Legend Y yes acceptable N no remove from service R repaired Checklist A Y N R A 1 Inspect the manuals and decals A 2 Pre operation inspection A 3 Function tests Perform after 40 hours A 4 30 day service Perform every 100 hours A 5 Grease rotation bearing Perform after 150 hours A 6 Drive hub oil Checklist B Y N R B 1 Battery B 2 Electrical wiring B 3 Tires ...

Page 32: ... could result in unsafe operating conditions 1 Check to make sure that the operator s and safety manuals are present and complete in the storage container on the platform 2 Examine the pages of each manual to be sure that they are legible and in good condition Result The operator s manual is appropriate for the machine and all manuals are legible and in good condition Result The operator s manual ...

Page 33: ...ion also serves to determine if routine maintenance procedures are required Complete information to perform this procedure is available in the appropriate operator s manual Refer to the Operator s Manual on your machine A 3 Perform Function Tests Genie specifications require that this procedure be performed every 8 hours or daily whichever comes first Completing the function tests is essential to ...

Page 34: ...rformed every 100 hours of operation Perform this procedure more often if dusty conditions exist Frequent application of lubrication to the turntable bearing and rotate gear is essential to good machine performance and service life Continued use of an improperly greased bearing and gear will result in component damage 1 Locate the grease fitting on the tank side turntable cover bulkhead 2 Pump gre...

Page 35: ...and service life Failure to replace the drive hub oil may cause the machine to perform poorly and continued use may cause component damage 1 Select the drive hub to be serviced Drive the machine until one of the two plugs is at the lowest point 2 Remove the plugs and drain the oil into a suitable container 3 Drive the machine until one of the two plugs is at the highest point 1 drive hub plugs 4 F...

Page 36: ... Adding terminal protectors and a corrosion preventative sealant will help eliminate corrosion on the battery terminals and cables 3 Be sure that the battery retainers and cable connections are tight 4 Be sure that the battery separator wire connections are tight if equipped Models without maintenance free or sealed batteries 5 Put on protective clothing and eye wear 6 Remove the battery vent caps...

Page 37: ...eater than 0 1 OR the specific gravity of one or more cells is less than 1 177 Replace the battery 11 Check the battery acid level If needed replenish with distilled water to 1 8 inch 3 mm below the bottom of the battery fill tube Do not overfill 12 Install the vent caps and neutralize any electrolyte that may have spilled B 2 Inspect the Electrical Wiring Genie specifications require that this pr...

Page 38: ...ve motor controller located in the non steer end of the drive chassis Note Do not apply excessive amounts of dielectric grease to harness connectors pins or sockets B 3 Inspect the Tires Wheels and Lug Nut Torque Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining the tires and wheels including proper wheel fastener torque is...

Page 39: ... Check the Drive Hub Oil Level and Fastener Torque Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Failure to maintain proper drive hub oil levels may cause the machine to perform poorly and continued use may cause component damage 1 Drive the machine to rotate the hub until the plugs are located one on top and the other at 90 degree...

Page 40: ...3 Operate each boom function through a partial cycle at the ground controls Result All boom functions should operate B 7 Test the Platform Self leveling Note Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Automatic platform self leveling throughout the full cycle of boom raising and lowering is essential for safe machine operation T...

Page 41: ...ance between the test line and your machine reference point Refer to Specifications Performance Specifications Note The brakes must be able to hold the machine on any slope it is able to climb B 9 Test the Drive Speed Stowed Position Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Proper drive function is essential to safe machine op...

Page 42: ... on the machine i e contact patch of a tire as a visual reference for use when crossing the start and finish lines 3 Bring the machine to top drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line 4 Continue at full speed and note the time when the machine reference point crosses the finish line Refer to Specifications Performance Sp...

Page 43: ...hen release it Move the jib boom switch to the down position hold for a moment and then release it Result The descent alarm should sound when each switch is held down 3 Turn the key switch to platform control 4 At the platform controls pull out the red Emergency Stop button to the on position Result The flashing beacon should be on and flashing 5 Press down the foot switch Move the primary boom sw...

Page 44: ...int between the steer tires 3 Rotate the turntable to the right as far as it will go Result Movement should stop when the primary boom reaches midpoint between the steer tires B 13 Check the Electrical Contactors Note Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining the electrical contactors in good condition is essential ...

Page 45: ...ary If the hydraulic oil is not replaced at the two year inspection test the oil quarterly Replace the oil when it fails the test Refer to Maintenance Procedure Test or Replace the Hydraulic Oil B 15 Test the Emergency Power System Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Testing the emergency power system regularly is essenti...

Page 46: ...security tie and lift the emergency power switch cover if equipped 7 Press down on the foot switch and simultaneously hold the emergency power switch on and activate each boom function Note To conserve battery power test each function through a partial cycle Result All boom functions operate 8 Close the emergency power switch cover and secure the cover with a security tie if equipped ...

Page 47: ...ure be performed every 500 hours or six months whichever comes first OR when the machine fails to lift the maximum rated load Testing the platform overload system regularly is essential to safe machine operation Continued use of an improperly operating platform overload system could result in the system not sensing an overloaded platform condition Machine stability could be compromised resulting i...

Page 48: ...icator lights flash and the alarm sounds 7 Carefully move the test weights to each remaining location on the platform Refer to Illustration 1 Result The platform overload indicator lights should be flashing at both the ground and platform controls and the alarm should sound Note There may be a 2 second delay before the overload indicator lights flash and the alarm sounds 8 Turn the key switch to g...

Page 49: ...r pad Replace the wear pad once it reaches the minimum allowable thickness If the wear pad is still within specification shim as necessary to obtain minimum clearance with zero binding 2 Extend and retract the boom through the entire range of motion to check for tight spots that may cause binding or scraping of the boom Note Always maintain squareness between the outer and inner boom tubes Models ...

Page 50: ...exceed 2 mph 3 2 km h 1 Chock the steer wheels to prevent the machine from rolling 2 Center a lifting jack of ample capacity 20 000 lbs 10 000 kg under the drive chassis between the non steer tires 3 Lift the wheels off the ground and then place jack stands under the drive chassis for support 4 Disengage the drive hubs by turning over the drive hub disconnect caps on each non steer wheel hub 1 bra...

Page 51: ...e boom onto the lift cylinder safety chock Crushing hazard Keep hands away from the cylinder and all moving parts when lowering the boom Note The lift cylinder safety chock is available through Genie Parts Department 2 Confirm that each turntable mounting bolt is torqued in sequence to specification Refer to Specifications Machine Torque Specifications Bolt torque sequence 3 Raise the secondary bo...

Page 52: ...ne Specifications 5 Repeat this procedure for each drive hub D 5 Replace the Hydraulic Tank Return Filter Element Note Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first Perform this procedure more often if dusty conditions exist Replacement of the hydraulic return filter element is essential for good machine performance and service lif...

Page 53: ...ble bearing wear is essential to safe machine operation good machine performance and service life Continued use of a worn turntable bearing could create an unsafe operating condition resulting in death or serious injury and component damage Note Perform this procedure with the machine on a firm level surface with the boom in the stowed position 1 Grease the turntable bearing Refer to Maintenance P...

Page 54: ...edure be performed every 2000 hours or every two years whichever comes first Perform this procedure more often if dusty conditions exist Replacement or testing of the hydraulic oil is essential for good machine performance and service life Dirty oil and a clogged suction strainer or hydraulic filters may cause the machine to perform poorly and continued use may cause component damage Extremely dir...

Page 55: ...n the valve on the hydraulic tank and completely drain the oil into a suitable container Bodily injury hazard Beware of hot oil Contact with hot oil may cause severe burns 5 ag disconnect and plug the hydraulic hoses from the hydraulic tank return filter housing Cap the fittings on the filter housing Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connectio...

Page 56: ... specifications require that this procedure be performed every 2000 hours or every two years whichever comes first Perform this procedure more often if dusty conditions exist Maintaining the steer axle wheel bearings is essential for safe machine operation and service life Operating the machine with loose or worn wheel bearings may cause an unsafe operating condition and continued use may result i...

Page 57: ...move the castle nut 12 Pull the hub off of the spindle The washer and outer bearing should fall loose from the hub 13 Place the hub on a flat surface and gently pry the bearing seal out of the hub Remove the rear bearing 14 Pack both bearings with clean fresh grease 15 Place the large inner bearing into the rear of the hub 16 Install a new bearing grease seal into the hub by pressing it evenly int...

Page 58: ...anual 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 parked on ...

Page 59: ...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 which if ...

Page 60: ...pport 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 D...

Page 61: ...unterclockwise 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 press do...

Page 62: ...in 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 hydraulic con...

Page 63: ...ing 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 machine ...

Page 64: ...l 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 to safe ...

Page 65: ... 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 indicator lig...

Page 66: ...ing 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 should operat...

Page 67: ...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 Do not al...

Page 68: ...ead 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 Hose and F...

Page 69: ...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 appropriate li...

Page 70: ...and move and hold the jib boom rotate toggle switch to the left for approximately 5 seconds then release it Repeat three times 4 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 of the pla...

Page 71: ...dily 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 the levelin...

Page 72: ...forming major repairs that involve removing the primary boom How to R epair the Primary Boom C abl e Tr ack 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 screwdriver to pry ...

Page 73: ...his 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 during insta...

Page 74: ...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 counterweigh...

Page 75: ... could become unbalanced and fall when removed from the machine if not properly attached to the overhead crane How to Disassembl e the Primary 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 Procedure How ...

Page 76: ... 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 specific repa...

Page 77: ...etal 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 machine a...

Page 78: ...r 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 skills an...

Page 79: ...oom 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 pin 11 Care...

Page 80: ...rqued 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 skin Loo...

Page 81: ...20N Z 30 20N RJ Z 34 22 Z 34 22N Part No 139378 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 82: ...ry 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 platform contro...

Page 83: ... 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 Remove th...

Page 84: ...ntact 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 Beware of...

Page 85: ...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 Remove the...

Page 86: ... 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 compression a...

Page 87: ...cifications 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 on the aux...

Page 88: ... 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 barrel en...

Page 89: ...nder 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 attached...

Page 90: ...welry 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 from the pu...

Page 91: ...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 ft lbs 1...

Page 92: ...April 2016 Service Manual Manifolds Part No 139378 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N 79 ...

Page 93: ...N 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 gpm 6 8 L...

Page 94: ...April 2016 Service Manual Manifolds Part No 139378 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N 81 ...

Page 95: ...er than specified 6 Repeat steps 2 and 3 to confirm the relief valve pressure setting 7 Remove the pressure gauge How to Adj ust the Primary Boom Dow n R elief 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 3000 psi 0 ...

Page 96: ...ot 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 Adj ust the Primary Boom Extend R elief Valve 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 the function...

Page 97: ...n 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 and remove...

Page 98: ...ion 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 0 025 inch ...

Page 99: ...ption 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 0 025 inc...

Page 100: ...oil 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 valve coil...

Page 101: ... 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 Dotted lines...

Page 102: ...ections 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 103: ... 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 oil can p...

Page 104: ...g Note When removing a bearing always use a new inner bearing seal How to Install the H ub and Bearings 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 a new beari...

Page 105: ...orque 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 106: ...e 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 connector fro...

Page 107: ...s 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 that all ne...

Page 108: ...t 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 located behind ...

Page 109: ... 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 mot...

Page 110: ...e 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 to ground ...

Page 111: ... 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 battery cables...

Page 112: ...ey 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 all ring...

Page 113: ...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 switch norma...

Page 114: ...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 ratio Sol...

Page 115: ...Service Manual April 2016 Limit Switch Location Legend 102 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N Part No 139378 ...

Page 116: ...April 2016 Service Manual 103 Power Cable Wiring Diagram ...

Page 117: ...Service Manual April 2016 104 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N Part No 139378 Power Cable Wiring Diagram ...

Page 118: ...April 2016 Service Manual Part No 139378 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N 105 Drive Contactor Panel Wiring Diagram ...

Page 119: ...Service Manual April 2016 106 Drive Contactor Panel Wiring Diagram ...

Page 120: ...April 2016 Service Manual 107 Manifold and Limit Switch Wiring Diagram ...

Page 121: ...Service Manual April 2016 108 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N Part No 139378 Manifold and Limit Switch Wiring Diagram ...

Page 122: ...April 2016 Service Manual Part No 139378 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N 109 LVI BCI Option Wiring Diagram ...

Page 123: ...Service Manual April 2016 110 LVI BCI Option Wiring Diagram ...

Page 124: ...April 2016 Service Manual 111 Work and Drive Lights Option ...

Page 125: ...Service Manual April 2016 112 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N Part No 139378 Work and Drive Lights Option ...

Page 126: ...April 2016 Service Manual Part No 139378 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N 113 CTE Option CE Models ...

Page 127: ...Service Manual April 2016 114 CTE Option CE Models ...

Page 128: ...April 2016 Service Manual 115 Charger Interlock Option ...

Page 129: ...Service Manual April 2016 116 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N Part No 139378 Charger Interlock Option ...

Page 130: ...April 2016 Service Manual 117 Hydraulic Schematic ...

Page 131: ...Service Manual April 2016 118 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N Part No 139378 Hydraulic Schematic ...

Page 132: ...April 2016 Service Manual 119 Electrical Schematic ANSI CSA AS before serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 ...

Page 133: ...Service Manual April 2016 120 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N Part No 139378 Electrical Schematic ANSI CSA AS before serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 ...

Page 134: ...April 2016 Service Manual Part No 139378 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N 121 Electrical Schematic ANSI CSA AS before serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 ...

Page 135: ...Service Manual April 2016 122 Electrical Schematic ANSI CSA AS before serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 ...

Page 136: ...April 2016 Service Manual 123 Ground Control Box Terminal Strip Wiring Diagram ANSI CSA AS before serial numbers Z3010 12119 Z34N10 8857 and Z3410 7774 ...

Page 137: ...ervice Manual April 2016 124 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N Part No 139378 Ground Control Box Terminal Strip Wiring Diagram ANSI CSA AS before serial numbers Z3010 12119 Z34N10 8857 and Z3410 7774 ...

Page 138: ...pril 2016 Service Manual Part No 139378 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N 125 Ground Control Box Switch Panel Wiring Diagram ANSI CSA AS before serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 ...

Page 139: ...Service Manual April 2016 126 Ground Control Box Switch Panel Wiring Diagram ANSI CSA AS before serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 ...

Page 140: ...April 2016 Service Manual 127 Platform Control Box Wiring Diagram ANSI CSA AS before serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 ...

Page 141: ...Service Manual April 2016 128 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N Part No 139378 Platform Control Box Wiring Diagram ANSI CSA AS before serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 ...

Page 142: ...April 2016 Service Manual 129 Electrical Schematic CE before serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 ...

Page 143: ...Service Manual April 2016 130 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N Part No 139378 Electrical Schematic CE before serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 ...

Page 144: ...April 2016 Service Manual Part No 139378 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N 131 Electrical Schematic CE before serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 ...

Page 145: ...Service Manual April 2016 132 Electrical Schematic CE before serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 ...

Page 146: ...April 2016 Service Manual 133 Ground Control Box Terminal Strip Wiring Diagram CE before serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 ...

Page 147: ...Service Manual April 2016 134 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N Part No 139378 Ground Control Box Terminal Strip Wiring Diagram CE before serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 ...

Page 148: ...April 2016 Service Manual Part No 139378 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N 135 Ground Control Box Switch Panel Wiring Diagram CE before serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 ...

Page 149: ...Service Manual April 2016 136 Ground Control Box Switch Panel Wiring Diagram CE before serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 ...

Page 150: ...April 2016 Service Manual 137 Platform Control Box Wiring Diagram CE before serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 ...

Page 151: ...Service Manual April 2016 138 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N Part No 139378 Platform Control Box Wiring Diagram CE before serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 ...

Page 152: ...April 2016 Service Manual 139 Electrical Schematic ANSI CSA from serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 to Z30N13 14695 Z34N13 10622 and Z3413 9441 ...

Page 153: ... Manual April 2016 140 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N Part No 139378 Electrical Schematic ANSI CSA from serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 to Z30N13 14695 Z34N13 10622 and Z3413 9441 ...

Page 154: ...016 Service Manual Part No 139378 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N 141 Electrical Schematic ANSI CSA from serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 to Z30N13 14695 Z34N13 10622 and Z3413 9441 ...

Page 155: ...Service Manual April 2016 142 Electrical Schematic ANSI CSA from serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 to Z30N13 14695 Z34N13 10622 and Z3413 9441 ...

Page 156: ...April 2016 Service Manual 143 Electrical Schematic ANSI CSA from serial numbers Z30N13 14696 Z34N13 10623 and Z3413 9442 to Z30N14 15221 Z34N14 10983 and Z3414 9685 ...

Page 157: ...Manual April 2016 144 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N Part No 139378 Electrical Schematic ANSI CSA from serial numbers Z30N13 14696 Z34N13 10623 and Z3413 9442 to Z30N14 15221 Z34N14 10983 and Z3414 9685 ...

Page 158: ...16 Service Manual Part No 139378 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N 145 Electrical Schematic ANSI CSA from serial numbers Z30N13 14696 Z34N13 10623 and Z3413 9442 to Z30N14 15221 Z34N14 10983 and Z3414 9685 ...

Page 159: ...Service Manual April 2016 146 Electrical Schematic ANSI CSA from serial numbers Z30N13 14696 Z34N13 10623 and Z3413 9442 to Z30N14 15221 Z34N14 10983 and Z3414 9685 ...

Page 160: ...April 2016 Service Manual 147 Ground Control Box Terminal Strip Wiring Diagram ANSI CSA from serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 to Z30N13 14695 Z34N13 10622 and Z3413 9441 ...

Page 161: ...2016 148 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N Part No 139378 Ground Control Box Terminal Strip Wiring Diagram ANSI CSA from serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 to Z30N13 14695 Z34N13 10622 and Z3413 9441 ...

Page 162: ...April 2016 Service Manual Part No 139378 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N 149 Ground Control Box Switch Panel Wiring Diagram ANSI CSA from serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 ...

Page 163: ...Service Manual April 2016 150 Ground Control Box Switch Panel Wiring Diagram ANSI CSA from serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 ...

Page 164: ...April 2016 Service Manual 151 Ground Control Box Terminal Strip Wiring Diagram ANSI CSA from serial numbers Z30N13 14696 Z34N13 10623 and Z3413 9442 to Z30N14 15221 Z34N14 10983 and Z3414 9685 ...

Page 165: ...016 152 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N Part No 139378 Ground Control Box Terminal Strip Wiring Diagram ANSI CSA from serial numbers Z30N13 14696 Z34N13 10623 and Z3413 9442 to Z30N14 15221 Z34N14 10983 and Z3414 9685 ...

Page 166: ...ice Manual Part No 139378 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N 153 Platform Control Box Wiring Diagram ANSI CSA from serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 to Z30N13 14695 Z34N13 10622 and Z3413 9441 ...

Page 167: ...April 2016 154 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N Part No 139378 Platform Control Box Wiring Diagram ANSI CSA from serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 to Z30N13 14695 Z34N13 10622 and Z3413 9441 ...

Page 168: ...ice Manual Part No 139378 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N 155 Platform Control Box Wiring Diagram ANSI CSA from serial numbers Z30N13 14696 Z34N13 10623 and Z3413 9442 to Z30N14 15221 Z34N14 10983 and Z3414 9685 ...

Page 169: ...Service Manual April 2016 156 Platform Control Box Wiring Diagram ANSI CSA from serial numbers Z30N13 14696 Z34N13 10623 and Z3413 9442 to Z30N14 15221 Z34N14 10983 and Z3414 9685 ...

Page 170: ...April 2016 Service Manual 157 ...

Page 171: ...e Manual April 2016 158 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N Part No 139378 Electrical Schematic AS CE from serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 to Z30N13 14695 Z34N13 10622 and Z3413 9441 ...

Page 172: ...2016 Service Manual Part No 139378 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N 159 Electrical Schematic AS CE from serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 to Z30N13 14695 Z34N13 10622 and Z3413 9441 ...

Page 173: ...Service Manual April 2016 160 Electrical Schematic AS CE from serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 to Z30N13 14695 Z34N13 10622 and Z3413 9441 ...

Page 174: ...April 2016 Service Manual 161 Electrical Schematic AS CE from serial numbers Z30N13 14696 Z34N13 10623 and Z3413 9442 to Z30N14 15221 Z34N14 10983 and Z3414 9685 ...

Page 175: ...e Manual April 2016 162 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N Part No 139378 Electrical Schematic AS CE from serial numbers Z30N13 14696 Z34N13 10623 and Z3413 9442 to Z30N14 15221 Z34N14 10983 and Z3414 9685 ...

Page 176: ...2016 Service Manual Part No 139378 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N 163 Electrical Schematic AS CE from serial numbers Z30N13 14696 Z34N13 10623 and Z3413 9442 to Z30N14 15221 Z34N14 10983 and Z3414 9685 ...

Page 177: ...Service Manual April 2016 164 Electrical Schematic AS CE from serial numbers Z30N13 14696 Z34N13 10623 and Z3413 9442 to Z30N14 15221 Z34N14 10983 and Z3414 9685 ...

Page 178: ...April 2016 Service Manual 165 Ground Control Box Terminal Strip Wiring Diagram AS CE from serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 to Z30N13 14695 Z34N13 10622 and Z3413 9441 ...

Page 179: ... 2016 166 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N Part No 139378 Ground Control Box Terminal Strip Wiring Diagram AS CE from serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 to Z30N13 14695 Z34N13 10622 and Z3413 9441 ...

Page 180: ...Manual Part No 139378 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N 167 Ground Control Box Switch Panel Wiring Diagram AS CE from serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 to Z30N13 14695 Z34N13 10622 and Z3413 9441 ...

Page 181: ...Service Manual April 2016 168 Ground Control Box Switch Panel Wiring Diagram AS CE from serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 to Z30N13 14695 Z34N13 10622 and Z3413 9441 ...

Page 182: ...April 2016 Service Manual 169 Ground Control Box Terminal Strip Wiring Diagram AS CE from serial numbers Z30N13 14696 Z34N13 10623 and Z3413 9442 to Z30N14 15221 Z34N14 10983 and Z3414 9685 ...

Page 183: ... 2016 170 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N Part No 139378 Ground Control Box Terminal Strip Wiring Diagram AS CE from serial numbers Z30N13 14696 Z34N13 10623 and Z3413 9442 to Z30N14 15221 Z34N14 10983 and Z3414 9685 ...

Page 184: ...rvice Manual Part No 139378 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N 171 Platform Control Box Wiring Diagram AS CE from serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 to Z30N13 14695 Z34N13 10622 and Z3413 9441 ...

Page 185: ...l April 2016 172 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N Part No 139378 Platform Control Box Wiring Diagram AS CE from serial numbers Z30N10 12119 Z34N10 8857 and Z3410 7774 to Z30N13 14695 Z34N13 10622 and Z3413 9441 ...

Page 186: ...vice Manual Part No 139378 Z 30 20N Z 30 20N RJ Z 34 22 Z 34 22N 173 Platform Control Box Wiring Diagram AS CE from serial numbers Z30N13 14696 Z34N13 10623 and Z3413 9442 to Z30N14 15221 Z34N14 10983 and Z3414 9685 ...

Page 187: ...4 Platform Control Box Wiring Diagram AS CE from serial numbers Z30N13 14696 Z34N13 10623 and Z3413 9442 to Z30N14 15221 Z34N14 10983 and Z3414 9685 Z 30 20N Z 30 20N R J Z 34 22 Z 34 22N Part No 139378 Service M anual April 2016 ...

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