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Genie Z-34/22N Service Manual

Genie Z-34/22N
188 pages
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Service Manual
Serial Number Range
from Z30N08-11500 to
Z30N14-
15221
from Z34N07-6291 to
Z34N14- 10983
from Z3407-5427 to
Z3414-
9685
Part No. 139378
Rev C1
April 2016

Table of Contents

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Genie Z-34/22N Specifications

General IconGeneral
Working Height12.52 m
Platform Height10.52 m
Horizontal Reach6.78 m
Lift Capacity227 kg
Platform Rotation180°
Turntable Rotation355° Non-Continuous
Power Source48 V DC (eight 6 V batteries) or Kubota Diesel Engine
Stowed Height2.00 m
Drive Speed - Raised1.1 km/h
Maximum Platform Height10.52 m
Platform Length0.76 m
Drive Speed - Stowed6.0 km/h
TyresSolid Rubber
Fuel TypeDiesel

Summary

Introduction to Genie Service Manual

Important Safety and Operating Information

Safety rules and operating instructions are key for maintenance.

Technical Publications and Continuous Improvement

Information accuracy and continuous improvement policy.

Contacting Genie for Support

How to get in touch with Genie for support.

Finding Model-Specific Manuals

Instructions to locate manuals on the Genie website.

Serial Number Legend

Genie Safety Rules and Precautions

Critical Danger Warnings

Warning about death or serious injury from not following safety rules.

Conditions for Performing Maintenance

Conditions required before performing maintenance procedures.

Personal Safety Awareness

Awareness of hazards for personnel working on or around machines.

Workplace Safety Guidelines

Awareness of hazards for personnel working in the workplace.

Machine Specifications Overview

Detailed Machine Specifications

Details on tires, wheels, load range, dimensions, and fuel capacities.

Wheel Lug Nut Torque Specifications

Torque specifications for wheel lug nuts.

Hydraulic System Fuel Capacities

Capacities for hydraulic tank and system.

Machine Component Weights

Weights of various machine components for different models.

Performance Specifications

Drive speed, braking distance, and boom function speeds for models.

Hydraulic Oil and Fluid Specifications

Requirements for hydraulic oils and optional fluids.

Hydraulic Fluid Temperature Ranges

Temperature ranges for various hydraulic fluids.

Hydraulic Fluid Properties

Properties of various hydraulic fluids including Chevron and Shell.

Hydraulic Component and Manifold Specifications

Specifications for pumps, plugs, and valve coil resistance.

Machine Torque Specifications

Torque values for various components like rotators, bearings, hubs, brakes, and motors.

Hydraulic Hose and Fitting Torque

Torque specifications for Seal-Lok™ and JIC 37° fittings, and O-ring boss ports.

Torque Procedure Guidelines

Procedures for torqueing Seal-Lok™ and JIC 37° fittings.

Scheduled Maintenance Procedures Guide

Required Machine Configuration for Maintenance

Specific configuration required for performing maintenance procedures.

General Maintenance Rules and Schedule

General rules to follow before performing maintenance.

Maintenance Schedule Overview

Chart detailing inspection frequency based on hours or time.

Checklist A: Basic Procedures

Inspect manuals/decals, perform pre-operation inspection and function tests.

Checklist B: System Checks

Inspect battery, wiring, tires, brakes, drive hubs, and test self-leveling.

Checklist C: Overload System Tests

Grease and test the platform overload mechanism and system.

Checklist D: Component Inspections

Check boom wear pads, free-wheel config, bearing bolts, drive hub oil, and filters.

Checklist E: Fluid and Bearing Service

Test or replace hydraulic oil and grease steer axle wheel bearings.

Repair Procedures Guidelines

Preparation Before Starting Repairs

Steps to take before starting repair procedures, including safety.

Repair Procedures Section Overview

Overview of the repair procedures section.

Symbols Legend for Repair Procedures

Explanation of symbols used in the repair procedures.

Platform Controls and Components

Controllers and Speed Adjustments

Information about drive joystick and boom function speed controller adjustments.

Platform Leveling Slave Cylinder Service

Function, removal, and bleeding of the platform leveling slave cylinder.

Platform Rotator Service Procedures

Information, removal, and bleeding of the platform rotator.

Platform Overload System Calibration

Steps to calibrate the platform overload system for safe operation.

Boom Components Service

Jib Boom Removal and Bell Crank Service

Information and steps for removing the jib boom and bell crank.

Jib Boom Rotator Service

Information and steps for removing the jib boom rotator.

Jib Boom Lift Cylinder Removal

Information and steps for removing the jib boom lift cylinder.

Primary Boom Cable Track Repair

Steps to repair the primary boom cable track.

Primary Boom Shimming and Removal

Procedure for shimming and removing the primary boom.

Primary Boom Disassembly

Steps to disassemble the primary boom.

Primary Boom Lift Cylinder Removal

Information and steps for removing the primary boom lift cylinder.

Primary Boom Extension Cylinder Removal

Information and steps for removing the primary boom extension cylinder.

Platform Leveling Master Cylinder Removal

Information and steps for removing the platform leveling master cylinder.

Secondary Boom Components and Service

Secondary Boom Disassembly

Steps to disassemble the secondary boom.

Secondary Boom Lift Cylinder Removal

Information and steps for removing the secondary boom lift cylinder.

Hydraulic Pump Service

Auxiliary and Function Pump Removal

Information and steps for removing the auxiliary or function pump.

Manifold Systems and Valve Adjustments

Function Manifold Components

Components of the function manifold with schematic items and torque.

Function Manifold Valve Adjustments

Procedures for adjusting system, primary boom, and secondary boom relief valves.

Turntable Rotate Relief Valve Adjustment

Procedure to adjust the turntable rotate relief valve.

Jib Boom and Platform Rotate Manifold Components

Components for jib boom/platform rotate manifold based on serial numbers.

Valve Coil Testing

Procedure to test valve coil resistance and diodes.

Turntable Rotation Components

Turntable Rotation Hydraulic Motor Service

Information and steps to remove the turntable rotation hydraulic motor.

Axle Components Service

Steer Axle Hub and Bearings Service

Information, removal, and installation of hub and bearings for 2WD models.

Non-steer Axle Motor Controller Testing

Information and procedure to test the motor controller.

Troubleshooting Fault Codes

Before Troubleshooting Faults

Steps to take before troubleshooting fault codes, including safety.

Understanding Fault Codes

Explanation of fault codes and their meaning indicated by controller lights.

Fault Code Chart and Solutions

Table listing fault codes, conditions, causes, and solutions.

Schematics and Symbol Legends

Electrical and Hydraulic Schematics Overview

Overview of the electrical and hydraulic schematics sections.

Electrical Symbol Legend

Explanation of electrical symbols used in diagrams.

Hydraulic Symbols Legend

Explanation of hydraulic symbols used in diagrams.

Wiring Diagrams

Power Cable Wiring Diagram

Diagram illustrating the power cable connections.

Drive Contactor Panel Wiring Diagram

Wiring diagram for the drive contactor panel.

Manifold and Limit Switch Wiring Diagram

Wiring diagram for manifolds and limit switches.

LVI/BCI Option Wiring Diagram

Wiring diagram for the LVI/BCI option.

Work and Drive Lights Option Wiring

Information about the work and drive lights option.

CTE Option, (CE Models) Wiring

Information about the CTE option for CE models.

Charger Interlock Option Wiring

Information about the charger interlock option.

Hydraulic Schematic Diagram

Overall hydraulic schematic of the machine.

Electrical Schematics by Model and Serial Number

Electrical schematics for ANSI/CSA/AS and CE models across serial ranges.

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